Torque optimization for surgical instruments

ABSTRACT

A control system having speed management control. The control system can be in signal communication with a battery, and the battery can be coupled to a motor. The speed management control can include a pulse width modulation circuit, which can control the duration of pulses supplied from the battery to the motor. The motor can include a primary set of coils and a secondary set of coils. The control system can direct surplus current to the secondary set of coils to maximize the torque generated by the motor.

FIELD OF THE INVENTION

The present invention relates to surgical instruments and, in variousarrangements, to powered surgical cutting and stapling instruments andstaple cartridges therefor that are designed to cut and staple tissue.

BACKGROUND

Surgical staplers are often used to deploy staples into soft tissue toreduce or eliminate bleeding from the soft tissue, especially as thetissue is being transected, for example. Surgical staplers, such as anendocutter, for example, can comprise an end effector which can bemoved, or articulated, with respect to an elongated shaft assembly. Endeffectors are often configured to secure soft tissue between first andsecond jaw members where the first jaw member often includes a staplecartridge which is configured to removably store staples therein and thesecond jaw member often includes an anvil. Such surgical staplers caninclude a closing system for pivoting the anvil relative to the staplecartridge.

Surgical staplers, as outlined above, can be configured to pivot theanvil of the end effector relative to the staple cartridge in order tocapture soft tissue therebetween. In various circumstances, the anvilcan be configured to apply a clamping force to the soft tissue in orderto hold the soft tissue tightly between the anvil and the staplecartridge. If a surgeon is unsatisfied with the position of the endeffector, however, the surgeon must typically activate a releasemechanism on the surgical stapler to pivot the anvil into an openposition and then reposition the end effector. Thereafter, staples aretypically deployed from the staple cartridge by a driver which traversesa channel in the staple cartridge and causes the staples to be deformedagainst the anvil and secure layers of the soft tissue together. Often,as known in the art, the staples are deployed in several staple lines,or rows, in order to more reliably secure the layers of tissue together.The end effector may also include a cutting member, such as a knife, forexample, which is advanced between two rows of the staples to resect thesoft tissue after the layers of the soft tissue have been stapledtogether.

Such surgical staplers and effectors may be sized and configured to beinserted into a body cavity through a trocar or other access opening.The end effector is typically coupled to an elongated shaft that issized to pass through the trocar or opening. The elongated shaftassembly is often operably coupled to a handle that supports controlsystems and/or triggers for controlling the operation of the endeffector. To facilitate proper location and orientation of the endeffector within the body, many surgical instruments are configured tofacilitate articulation of the end effector relative to a portion of theelongated shaft.

Powered surgical instruments are disclosed in U.S. Patent ApplicationPublication No. US 2009/0090763 A1, entitled POWERED SURGICAL STAPLINGDEVICE to Zemlok et al. (hereinafter “Zemlok '763”), the entiredisclosure of which is hereby incorporated by reference herein. Poweredsurgical instruments are also disclosed in U.S. Patent ApplicationPublication No. US 2011/0278344 A1, entitled POWERED SURGICAL INSTRUMENTto Zemlok et al. (hereinafter “Zemlok '344”), now U.S. Pat. No.8,201,721, the entire disclosure of which is hereby incorporated byreference herein.

The foregoing discussion is intended only to illustrate various aspectsof the related art in the field of the invention at the time, and shouldnot be taken as a disavowal of claim scope.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and advantages of this invention, and the manner ofattaining them, will become more apparent and the invention itself willbe better understood by reference to the following description ofembodiments of the invention taken in conjunction with the accompanyingdrawings, wherein:

FIG. 1 is a perspective view of a surgical instrument employing one formof retraction arrangement;

FIG. 2 is a perspective view of an exemplary loading unit that may beemployed in connection with various surgical instruments disclosedherein;

FIG. 3 is an exploded perspective view of a portion of the loading unitdepicted in FIG. 2;

FIG. 4 is a top view of a portion of the surgical instrument of FIG. 1;

FIG. 5 is a partial side view of a portion of the surgical instrumentdepicted in FIG. 4 with the clutch assembly in a disengaged position;

FIG. 6 is a top view of a portion of a retraction assembly embodimentand retraction lever arrangement thereof;

FIG. 7 is a partial exploded view of one form of a drive unit withportions thereof shown in cross-section;

FIG. 8 is another top view of a portion of the surgical instrument withthe drive unit locking system in the locked position;

FIG. 9 is a top view of one form of a locking pawl assembly;

FIG. 10 is a side elevational view of the locking pawl assembly of FIG.9;

FIG. 11 is a bottom view of the locking pawl assembly of FIGS. 9 and 10;

FIG. 12 is a front view of a gear box housing embodiment;

FIG. 13 is a partial side cross-sectional view of a surgical instrumentembodiment with portions thereof shown in cross-section and with thedrive unit locking system in a locked orientation;

FIG. 14 is another partial side cross-sectional view of the surgicalinstrument of FIG. 13 with the drive unit locking system in an unlockedorientation;

FIG. 15 is a top view of another surgical instrument embodiment with aportion of the housing removed to expose a portion of the instrument'sdrive unit locking system arrangement;

FIG. 16 is a partial side cross-sectional view of the surgicalinstrument embodiment of FIG. 15 with portions thereof shown incross-section and with solid lines illustrating the drive unit lockingsystem in a locked orientation and with broken lines illustrating thedrive unit locking system in an unlocked orientation;

FIG. 17 is another partial top view of the surgical instrumentembodiment of FIGS. 15 and 16 with solid lines illustrating the positionof the retraction lever prior to actuation and broken lines illustratingthe position of the retraction lever after initial actuation;

FIG. 18 is another partial top view of the surgical instrumentembodiment of FIGS. 15-17 with broken lines illustrating the retractionlever in a fully actuated position;

FIG. 19 is a partial top view of a portion of another surgicalinstrument embodiment with a portion of the housing omitted to exposethe instrument's drive unit locking system and with solid linesdepicting the retraction lever in an un-actuated position and brokenlines illustrating the retraction lever after initial actuation;

FIG. 20 is a partial top view of another surgical instrument embodimentwith a portion of the housing omitted to expose the drive unit lockingsystem thereof in a locked orientation;

FIG. 21 is another partial top view of the surgical instrumentembodiment of FIG. 20 with the drive unit locking system in an unlockedorientation;

FIG. 22 is a partial cross-sectional side view of a portion of asurgical instrument and end effector with the retraction assemblythereof in an unactuated orientation;

FIG. 23 is another partial cross-sectional side view of the surgicalinstrument and end effector of FIG. 22 after the firing rod assembly hasbeen fired;

FIG. 24 is another partial cross-sectional side view of the surgicalinstrument and end effector of FIG. 23 and after the retraction assemblyhas been actuated to retract the drive beam back to its startingposition within the end effector;

FIG. 25 is a partial cross-sectional side view of a portion of anothersurgical instrument and end effector in a prefire condition and with theretraction assembly thereof in an unactuated orientation;

FIG. 26 is another partial cross-sectional side view of the surgicalinstrument and end effector of FIG. 25 after firing;

FIG. 27 is another partial cross-sectional side view of the surgicalinstrument and end effector of FIG. 26 with the latch of the retractionassembly thereof in an unlatched orientation;

FIG. 28 is another partial cross-sectional side view of the surgicalinstrument and end effector of FIG. 27 with the distal firing rodportion in a retracted orientation;

FIG. 29 is a partial cross-sectional view of a portion of anothersurgical instrument embodiment with the drive coupler assembly thereofin an articulation orientation;

FIG. 30 is a partial cross-sectional view of a portion of the surgicalinstrument embodiment of FIG. 29 with the drive coupler assembly thereofin a firing orientation;

FIG. 31 is an enlarged cross-sectional view of the drive couplerassembly of the surgical instrument of FIGS. 29 and 30 with the couplerselector member shown in solid lines in the articulation orientation andwith the coupler selector member shown in broken lines in a firingorientation;

FIG. 32 is a partial cross-sectional view of a portion of anothersurgical instrument embodiment;

FIG. 33 is an enlarged partial cross-sectional view of a portion of thesurgical instrument of FIG. 32;

FIG. 34 is another enlarged partial cross-sectional view of a portion ofthe surgical instrument of FIGS. 32 and 33 with the travel limiterthereof in its distal-most orientation;

FIG. 35 is another enlarged partial cross-sectional view of a portion ofthe surgical instrument of FIGS. 32-34 with the travel limiter thereofin its proximal-most orientation;

FIG. 36 is a partial cross-sectional view of the surgical instrument ofFIG. 33 taken along line 36-36 in FIG. 33;

FIG. 37 is a partial perspective view of a portion of the surgicalinstrument of FIGS. 32-36;

FIG. 38 is a partial perspective view of a shaft of a surgicalinstrument, a collar, and a disposable loading unit unattached to theshaft according to various embodiments of the present disclosure;

FIG. 39 is a partial perspective view of the shaft, the collar and thedisposable loading unit of FIG. 38, depicting the disposable loadingunit attached to the shaft;

FIG. 40 is a partial exploded perspective view of the shaft, the collar,and the disposable loading unit of FIG. 38;

FIG. 41 is another partial exploded perspective view of the shaft, thecollar, and the disposable loading unit of FIG. 38;

FIG. 42 is a perspective view of a distal attachment portion of thedisposable loading unit of FIG. 38;

FIG. 43 is another perspective view of the distal attachment portion ofthe disposable loading unit of FIG. 38;

FIG. 44 is a perspective view of a proximal attachment portion of theshaft of FIG. 38;

FIG. 45 is another perspective view of the proximal attachment portionof the shaft of FIG. 38;

FIG. 46 is a perspective view of the collar and a firing shaft of thesurgical instrument of FIG. 38;

FIG. 47 is a partial perspective, cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit attached to the shaft;

FIG. 48 is a partial elevation, cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit unattached to the shaft;

FIG. 49 is a partial elevation, cross-section view of the disposableloading unit, the collar and the shaft of FIG. 38, depicting thedisposable loading unit attached to the shaft;

FIG. 50 is an elevation view of the collar and the shaft of FIG. 38taken along the plane indicated in FIG. 48;

FIG. 51 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit unattached to the shaft, and further depictingthe collar in an initial orientation relative to the shaft;

FIG. 52 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit unattached to the shaft, and further depictingthe collar in the initial orientation relative to the shaft;

FIG. 53 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit entering the shaft, and further depicting thecollar in the initial orientation relative to the shaft;

FIG. 54 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit entering the shaft, and further depicting thecollar in a secondary, rotated orientation relative to the shaft;

FIG. 55 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit entering the shaft, and further depicting thecollar in the secondary, rotated orientation relative to the shaft;

FIG. 56 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit fully inserted into the shaft, and furtherdepicting the collar in the secondary, rotated orientation relative tothe shaft;

FIG. 57 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit fully inserted into the shaft, and furtherdepicting the collar in the initial orientation relative to the shaft;

FIG. 58 is a perspective, partial cross-section view of the disposableloading unit, the collar, and the shaft of FIG. 38, depicting thedisposable loading unit fully inserted into the shaft, and furtherdepicting the collar in the initial orientation relative to the shaft;

FIG. 59 is a partial, perspective, cross-section view of a shaft of asurgical instrument and a disposable loading unit unattached to theshaft according to various embodiments of the present disclosure;

FIG. 60 is a partial, perspective, cross-section view of the shaft andthe disposable loading unit of FIG. 59, depicting the disposable loadingunit partially-inserted into the shaft, and further depicting a latch inan unlatched position;

FIG. 61 is a partial, perspective, cross-section view of the shaft andthe disposable loading unit of FIG. 59, depicting the disposable loadingunit fully-inserted into the shaft, and further depicting the latch in alatched position;

FIG. 62 is a partial, elevation, cross-section view of the shaft and thedisposable loading unit of FIG. 59, depicting the disposable loadingunit fully-inserted into the shaft, and further depicting the latch inthe latched position;

FIG. 63 is a schematic of a torque-voltage curve according to variousembodiments of the present disclosure;

FIG. 64( a) is a schematic of high duty cycle pulses delivered by apulse width modulation circuit according to various embodiments of thepresent disclosure;

FIG. 64( b) is a schematic of low duty cycle pulses delivered by a pulsewidth modulation circuit according to various embodiments of the presentdisclosure;

FIG. 65( a) is a schematic of a firing element driven by the high dutycycle pulses of the pulse width modulation circuit of FIG. 64( a);

FIG. 65( b) is a schematic of a firing element driven by the low dutycycle pulses of the pulse width modulation circuit of FIG. 64( b);

FIGS. 66( a)-66(c) are schematics of pulse width modulation circuitshaving a primary set of coils and a secondary set of coils according tovarious embodiments of the present disclosure;

FIG. 67 is a graph depicting speed and torque throughout a firing strokeaccording to various embodiments of the present disclosure;

FIG. 68 is a graph depicting a speed limiting trial segment during afiring stroke according to various embodiments of the presentdisclosure;

FIGS. 69 and 70 are schematics of a simplified stepper motor accordingto various embodiments of the present disclosure;

FIGS. 71-73 are schematics of a hybrid stepper motor according tovarious embodiments of the present disclosure;

FIGS. 74( a)-74(c) are schematics of the hybrid stepper motor of FIGS.71-73 illustrating the changing polarities;

FIG. 75 is a perspective view of a display that includes a touch screenfor use with an endoscope according to various embodiments of thepresent disclosure;

FIG. 76 is an elevation view of a first layer of information fordepiction on the display of FIG. 75, wherein the first layer ofinformation includes video feedback of a disposable loading unit (DLU)attached to a surgical instrument as viewed by the endoscope;

FIG. 77 is an elevation view of a second layer of information fordepiction on the display of FIG. 75, wherein the second layer ofinformation includes a control panel for accepting input via the touchscreen;

FIG. 78 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76;

FIG. 79 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes numerical data related to theprogression of the knife and a visual representation of the progressionof the knife when the knife is near the beginning of a firing stroke;

FIG. 80 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes numerical data related to theprogression of the knife and a visual representation of the progressionof the knife when the knife is near the distal end of the firing stroke;

FIG. 81 is an elevation view of the second layer of information FIG. 77overlaying the first layer of information of FIG. 76, wherein the secondlayer of information includes a symbolic representation of the knifeoverlapping the detected position of the knife in the DLU depicted inthe first layer of information;

FIG. 82 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes a graphical representation of thespeed of the distally advancing knife during a firing stroke;

FIG. 83 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes a graphical representation of theclamping force exerted by the DLU jaws on the tissue along the length ofthe DLU jaws;

FIG. 84 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes numerical data related to theorientation of the DLU, and wherein the DLU depicted in the first layerof information is in an unarticulated orientation;

FIG. 85 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes numerical data related to theorientation of the DLU and a visual representation of the orientation ofthe DLU, and wherein the DLU depicted in the first layer of informationis in an articulated orientation;

FIG. 86 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76 illustratinginput from a user for adjusting the articulation of the DLU via thetouch screen of FIG. 75;

FIG. 87 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76 illustrating aschematic for controlling the DLU and further illustrating input from auser for adjusting the articulation of the DLU by manipulating theschematic via the touch screen of FIG. 75;

FIG. 88 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76 illustrating theDLU in an articulated orientation in the first layer of information inresponse to the user input illustrated in FIGS. 86 and 87;

FIG. 89 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76 illustratinginput from a user for controlling the closure of the moveable jaw viathe touch screen of FIG. 75;

FIG. 90 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76 illustrating themoveable jaw of the DLU in a clamped orientation in the first layer ofinformation in response to the user input depicted in FIG. 89;

FIG. 91 is an elevation view of a controller interface for the secondarylayer of information of FIG. 77;

FIG. 92 is an elevation view of the second layer of information of FIG.77 overlaying the first layer of information of FIG. 76, wherein thesecond layer of information includes the controller interface of FIG. 91and a progression bar;

FIG. 93 is a schematic illustrating a communication system for afeedback controller and the endoscope, the surgical instrument, and thedisplay of FIG. 75;

FIG. 94 is an exploded view of a surgical instrument system including ahandle and an end effector including a plurality of indicators inaccordance with at least one embodiment;

FIG. 95 is a partial elevational view of a handle of a surgicalinstrument system including a plurality of indicators in accordance withat least one embodiment;

FIG. 96 is a partial cross-sectional view of a handle of a surgicalinstrument system including a trigger lock in accordance with at leastone embodiment illustrated with the trigger lock in an unlockedcondition;

FIG. 97 is a partial cross-sectional view of the handle of FIG. 96illustrating the trigger lock in a locked condition;

FIG. 98 is a cross-sectional view of the trigger lock of FIG. 96illustrating the trigger lock in its unlocked condition;

FIG. 99 is a cross-sectional view of the trigger lock of FIG. 96illustrating the trigger lock in its locked condition;

FIG. 99A is a flow chart outlining an operating program of a controllerof a surgical instrument for assessing whether the surgical instrumenthas been exposed to a temperature which exceeds its thresholdtemperature and determining the manner in which to notify the user ofthe surgical instrument that the threshold temperature has beenexceeded;

FIG. 100 is a cross-sectional view of a handle of a surgical instrumentsystem including a trigger lock in a locked condition in accordance withat least one embodiment;

FIG. 101 is a cross-sectional detail view of the handle of FIG. 100illustrating the trigger lock in its locked condition;

FIG. 102 is another cross-sectional detail view of the handle of FIG.100 illustrating the trigger lock in an unlocked condition;

FIG. 103 is a perspective view of the trigger lock of FIG. 100illustrated in its locked condition;

FIG. 104 is a partial cross-sectional perspective view of a handle of asurgical instrument including a trigger lock in a locked condition inaccordance with at least one embodiment;

FIG. 105 is a partial cross-sectional perspective view of the handle ofFIG. 104 illustrated in an unlocked condition;

FIG. 106 is a partial cross-sectional left side view of the handle ofFIG. 104 illustrated in its locked condition;

FIG. 107 is a partial cross-sectional right side view of the handle ofFIG. 104 illustrated in its locked condition;

FIG. 108 is a partial cross-sectional left side view of the handle ofFIG. 104 illustrated in its unlocked condition;

FIG. 109 is a partial cross-sectional right side view of the handle ofFIG. 104 illustrated in its unlocked condition;

FIG. 110 is a process flow diagram illustrating the steps that acontroller of a surgical instrument can utilize to process a signalreceived from an end effector attached to the surgical instrument;

FIG. 110A is a schematic depicting an array of parameters which can besupplied from an end effector to a surgical instrument;

FIG. 111 is a process flow diagram illustrating the steps for using theend effector and surgical instrument of FIG. 110;

FIG. 112 is a schematic illustrating an interconnection between an endeffector and a shaft of a surgical instrument in accordance with atleast one embodiment;

FIG. 113 is a plan view of a printed circuit board of theinterconnection of FIG. 112;

FIG. 114 is a partial perspective view of an end effector of a surgicalinstrument in accordance with at least one embodiment;

FIG. 115 is a partial perspective view of the end effector of FIG. 114and a shaft of a surgical instrument;

FIG. 116 is a cross-sectional view of the end effector of FIG. 114attached to the shaft of FIG. 115;

FIG. 117 is a cross-sectional view of an interconnection between an endeffector and a shaft in accordance with at least one embodiment;

FIG. 118 is a cross-sectional view of an interconnection between an endeffector and a shaft in accordance with at least one embodiment;

FIG. 119 is a cross-sectional view of an interconnection between an endeffector and a shaft in accordance with at least one embodiment;

FIG. 120 is a detail view of the interconnection of FIG. 119;

FIG. 121 is a side view of an end effector comprising an anvil and ananvil position indicator in accordance with at least one embodimentillustrating the anvil in an open position;

FIG. 122 is a side view of the end effector of FIG. 121 illustrating theanvil in a partially-closed position;

FIG. 123 is another side view of the end effector of FIG. 121illustrating the anvil in a partially-closed position;

FIG. 124 is another side view of the end effector of FIG. 121illustrating the anvil in a partially-closed position;

FIG. 125 is a detail view of the anvil position indicator of FIG. 121depicting the anvil in the position illustrated in FIG. 121;

FIG. 126 is a detail view of the anvil position indicator of FIG. 121depicting the anvil in the position illustrated in FIG. 122;

FIG. 127 is a detail view of the anvil position indicator of FIG. 121depicting the anvil in the position illustrated in FIG. 123;

FIG. 128 is a detail view of the anvil position indicator of FIG. 121depicting the anvil in the position illustrated in FIG. 124;

FIG. 129 illustrates a cross-sectional side of view of a surgicalinstrument according to certain embodiments described herein;

FIG. 130 illustrates a power system for powering the surgical instrumentof FIG. 129, wherein the power system is in communication with a controlsystem of the surgical instrument of FIG. 129;

FIG. 131 illustrates a battery pack of the power system of FIG. 130connected to a charger base;

FIG. 132 illustrates a power management circuit of the power system ofFIG. 130;

FIG. 133 illustrates a schematic block diagram exemplifying operationparameters of the power system of FIG. 130;

FIG. 134 illustrates a perspective view of a power source of a surgicalinstrument according to various embodiments described herein;

FIG. 135 illustrates a perspective view of the power source of FIG. 134disassembled according to various embodiments described herein;

FIG. 136 illustrates a circuit diagram of a circuit of the power sourceof FIG. 134 including an intact breakable portion according to variousembodiments described herein;

FIG. 137 illustrates the circuit diagram of the circuit of FIG. 136 withthe breakable portion broken according to various embodiments describedherein;

FIG. 138 illustrates a block diagram of a system for protecting datastored in a memory from unauthorized access according to variousembodiments described herein;

FIG. 139 illustrates a perspective view of a power source of a surgicalinstrument including a covered data access portal;

FIG. 140 illustrates the data access portal of FIG. 139 in an uncoveredconfiguration;

FIG. 141 illustrates a perspective view of a power source of a surgicalinstrument including an internal data access portal;

FIG. 142 illustrates a block diagram of a system for protecting datastored in a memory from unauthorized access according to variousembodiments described herein;

FIG. 143 illustrates a perspective view of a power source of a surgicalinstrument according to various embodiments described herein;

FIG. 144 illustrates a perspective view of the power source of FIG. 143coupled to the surgical instrument;

FIG. 145 illustrates LEDs of the power source of FIG. 143 in differentconfigurations according to various embodiments described herein;

FIG. 146 illustrates a side view of a surgical instrument including ahousing in accordance with various embodiments described herein;

FIG. 147 illustrates a side view of the housing of FIG. 146 with anouter shell removed to expose detachable components secured to thehousing by securing members;

FIG. 148 illustrates a side view of the housing in FIG. 147 with thedetachable components removed from the housing;

FIG. 149 is a schematic depicting detectable indentations, notches, orimpressions of a barcode defined in a surface of an end effector;

FIG. 150 is a schematic of an exemplary bar code usable with a bar codereader;

FIG. 151 is a partial side view of a shaft of an end effector includinga bar code in accordance with at least one embodiment;

FIG. 152 is a partial elevational view of an end effector of a surgicalinstrument including a bar code in accordance with at least oneembodiment;

FIG. 153 is a partial perspective view of a handle of a surgicalinstrument including a bar code reader in accordance with at least oneembodiment;

FIG. 154 is a cross-sectional view of the bar code reader of FIG. 153illustrated with an end effector positioned therein;

FIG. 155 is an exploded perspective view of an end effector and a shaftof a surgical instrument in accordance with at least one embodiment;

FIG. 156 is an exploded perspective view of an end effector and a shaftof a surgical instrument in accordance with at least one embodimentwherein the end effector comprises portions of a firing memberreleasably locked together;

FIG. 157 is a partial perspective view of the firing member portions ofFIG. 156 locked together by a lock member;

FIG. 158 is a partial perspective view of the firing member portions andthe lock member of FIG. 156 illustrated with a portion of the firingmember removed to illustrate the lock member releasably locking thefiring member portions together;

FIG. 159 is an exploded view of the firing member of FIG. 156 and arelease actuator configured to move the lock member into an unlockedcondition and unlock the firing member portions;

FIG. 160 is a partial exploded view of an interconnection between therelease actuator of FIG. 159 and a corresponding shaft release actuator;

FIG. 161 is a cross-sectional view of the interconnection of FIG. 160;

FIG. 162 is an exploded perspective view of an assembly comprising amotor, a drive shaft, and a slip clutch configured to selectivelytransmit rotation between the motor and the drive shaft;

FIG. 163 is a cross-sectional view of the assembly of FIG. 162;

FIG. 164 is a perspective view of a biasing element of the slip clutchof FIG. 162;

FIG. 165 is a cross-sectional view of the assembly of FIG. 162illustrating a clutch element of the slip clutch in a neutral position;

FIG. 166 is a cross-sectional view of the assembly of FIG. 162illustrating the clutch element of FIG. 165 in a forward position;

FIG. 167 is a cross-sectional view of the assembly of FIG. 162illustrating the clutch element of FIG. 165 in a reverse position;

FIG. 168 is a perspective view of a motor and a gear assembly accordingto various embodiments of the present disclosure;

FIG. 169 is a perspective view of a motor, a gear assembly, and an audiofeedback generator according to various embodiments of the presentdisclosure;

FIG. 170 is an elevational view of a pick on a disk of the gear assemblyof FIG. 169, depicting the disk rotating in a clockwise direction andthe pick engaging a clicker of the audio feedback generator of FIG. 169according to various embodiments of the present disclosure;

FIG. 171 is an elevational view of a pick on a disk of the gear assemblyof FIG. 169, depicting the disk rotating in a counterclockwise directionand the pick engaging a clicker of the audio feedback generator of FIG.169 according to various embodiments of the present disclosure;

FIG. 172 is a perspective view of a motor, a gear assembly havingmultiple disks, and an audio feedback generator according to variousembodiments of the present disclosure;

FIG. 173 is a graphical depiction of feedback generated near the end ofa firing stroke by the audio feedback generator of FIG. 172 according tovarious embodiments of the present disclosure;

FIGS. 174 and 175 are graphical depictions of feedback generated nearthe articulation limit of a loading unit by the audio feedback generatorof FIG. 172 according to various embodiments of the present disclosure;

FIG. 176 is a schematic depicting an algorithm for operating a surgicalinstrument;

FIG. 177 is another schematic depicting an algorithm for operating asurgical instrument;

FIG. 178 is a schematic depicting an algorithm for operating a surgicalinstrument;

FIG. 179 is a circuit configured to indicate the voltage of a battery;

FIG. 180 is a flasher schematic configured to indicate that a battery ischarged;

FIG. 181 is a schematic of a diagnostic check for use with a surgicalinstrument in accordance with at least one embodiment;

FIG. 182 is a schematic illustrating the discharge of a battery and apower cutoff once the charge of the battery is below a minimum chargelevel;

FIG. 183 is a table of information that can be maintained which recordsthe operation and/or performance of a battery;

FIG. 184 is a schematic of a battery diagnostic circuit;

FIG. 185 is a perspective view of a sealed motor and gear assembly foruse with a surgical instrument according to various embodiments of thepresent disclosure; and

FIG. 186 is an exploded, elevational, cross-sectional view of the sealedmotor and gear assembly of FIG. 185 according to various embodiments ofthe present disclosure.

DETAILED DESCRIPTION

Applicant of the present application also owns the following patentapplications that were filed on even date herewith and which are eachherein incorporated by reference in their respective entireties:

U.S. patent application entitled FIRING MEMBER RETRACTION DEVICES FORPOWERED SURGICAL INSTRUMENTS, Attorney Docket No. END7293USNP/130016;

U.S. patent application entitled SECONDARY BATTERY ARRANGEMENTS FORPOWERED SURGICAL INSTRUMENTS, Attorney Docket No. END7294USNP/130017;

U.S. patent application entitled ERROR DETECTION ARRANGEMENTS FORSURGICAL INSTRUMENT ASSEMBLIES, Attorney Docket No. END7295USNP/130018;

U.S. patent application entitled ATTACHMENT PORTIONS FOR SURGICALINSTRUMENT ASSEMBLIES, Attorney Docket No. END7296USNP/130019;

U.S. patent application entitled TAMPER PROOF CIRCUIT FOR SURGICALINSTRUMENT BATTERY PACK, Attorney Docket No. END7297USNP/130020;

U.S. patent application entitled CLOSURE INDICATOR SYSTEMS FOR SURGICALINSTRUMENTS, Attorney Docket No. END7298USNP/130021;

U.S. patent application entitled SHROUD RETENTION ARRANGEMENT FORSTERILIZABLE SURGICAL INSTRUMENTS, Attorney Docket No.END7300USNP/130023;

U.S. patent application entitled CONDUCTOR ARRANGEMENTS FOR ELECTRICALLYPOWERED SURGICAL INSTRUMENTS WITH ROTATABLE END EFFECTORS, AttorneyDocket No. END7301USNP/130024;

U.S. patent application entitled END EFFECTOR DETECTION SYSTEMS FORSURGICAL INSTRUMENTS, Attorney Docket No. END7302USNP/130025;

U.S. patent application entitled FIRING TRIGGER LOCKOUT ARRANGEMENTS FORSURGICAL INSTRUMENTS, Attorney Docket No. END7303USNP/130026;

U.S. patent application entitled INTERACTIVE DISPLAYS, Attorney DocketNo. END7304USNP/130027; and

U.S. patent application entitled MOTOR-POWERED ARTICULATABLE SURGICALINSTRUMENTS, Attorney Docket No. END7305USNP/130028.

Certain exemplary embodiments will now be described to provide anoverall understanding of the principles of the structure, function,manufacture, and use of the devices and methods disclosed herein. One ormore examples of these embodiments are illustrated in the accompanyingdrawings. Those of ordinary skill in the art will understand that thedevices and methods specifically described herein and illustrated in theaccompanying drawings are non-limiting exemplary embodiments and thatthe scope of the various embodiments of the present invention is definedsolely by the claims. The features illustrated or described inconnection with one exemplary embodiment may be combined with thefeatures of other embodiments. Such modifications and variations areintended to be included within the scope of the present invention.

The terms “comprise” (and any form of comprise, such as “comprises” and“comprising”), “have” (and any form of have, such as “has” and“having”), “include” (and any form of include, such as “includes” and“including”) and “contain” (and any form of contain, such as “contains”and “containing”) are open-ended linking verbs. As a result, a surgicalsystem, device, or apparatus that “comprises,” “has,” “includes” or“contains” one or more elements possesses those one or more elements,but is not limited to possessing only those one or more elements.Likewise, an element of a system, device, or apparatus that “comprises,”“has,” “includes” or “contains” one or more features possesses those oneor more features, but is not limited to possessing only those one ormore features.

The terms “proximal” and “distal” are used herein with reference to aclinician manipulating the handle portion of the surgical instrument.The term “proximal” referring to the portion closest to the clinicianand the term “distal” referring to the portion located away from theclinician. It will be further appreciated that, for convenience andclarity, spatial terms such as “vertical”, “horizontal”, “up”, and“down” may be used herein with respect to the drawings. However,surgical instruments are used in many orientations and positions, andthese terms are not intended to be limiting and/or absolute.

Various exemplary devices and methods are provided for performinglaparoscopic and minimally invasive surgical procedures. However, theperson of ordinary skill in the art will readily appreciate that thevarious methods and devices disclosed herein can be used in numeroussurgical procedures and applications including, for example, inconnection with open surgical procedures. As the present DetailedDescription proceeds, those of ordinary skill in the art will furtherappreciate that the various instruments disclosed herein can be insertedinto a body in any way, such as through a natural orifice, through anincision or puncture hole formed in tissue, etc. The working portions orend effector portions of the instruments can be inserted directly into apatient's body or can be inserted through an access device that has aworking channel through which the end effector and elongated shaft of asurgical instrument can be advanced.

FIG. 1 illustrates a powered surgical instrument 10 that, in many ways,may be similar to those surgical instruments (including variousfeatures, components and subcomponents thereof) disclosed in, forexample, Zemlok '763 and/or Zemlok '344, which have each beenincorporated by reference herein in their respective entireties. Thesurgical instrument 10 depicted in FIG. 1 includes a housing 12 that hasa handle portion 14 for facilitating manual manipulation and operationof the instrument. Thus, the term “housing” as used herein may encompassa handheld or otherwise hand-manipulatable arrangement. However, theterm “housing” may also encompass portions of an automated surgicalinstrument system such as a robotically-controlled system that is notintended to be handheld but is otherwise manipulated and actuatable byvarious components, portions, and/or actuators of the system.

An elongated shaft assembly 16 in the form of an endoscopic portionprotrudes from the housing 12 and is configured for operable attachmentto a surgical end effector that is constructed to perform at least onesurgical procedure in response to applications of firing motionsthereto. Such surgical end effectors may comprise, for example,endocutters, graspers or other devices that may include a pair of jawswherein one jaw is selectively movable relative to the other jaw or insome configurations, both jaws are movable relative to each other. Byway of further example, the surgical end effector may comprise a deviceconfigured to cut and staple tissue such as a “loading unit” 20 as shownin FIGS. 2 and 3. Surgical end effectors, such as loading unit 20, forexample, can be releasably attached to the elongated shaft assembly 16of the powered surgical instrument 10, as described in greater detailherein.

FIGS. 2 and 3 illustrate one exemplary form of a loading unit 20 thatmay be employed with the surgical instrument 10. Such loading unit 20may be similar to those loading units disclosed in the aforementionedU.S. patent application Publications, which have been each hereinincorporated by reference in their entireties as well as those loadingunits disclosed in, for example, U.S. Patent Application Publication No.US 2012-0298719-A1, entitled SURGICAL STAPLING INSTRUMENTS WITHROTATABLE STAPLE DEPLOYMENT ARRANGEMENTS, the disclosure of which ishereby incorporated by reference in its entirety herein.

As can be seen in FIG. 2, the loading unit 20 includes an anvil assembly22 that is supported for pivotal travel relative to a carrier 24 thatoperably supports a staple cartridge 26 therein. A mounting assembly 28is pivotally coupled to the cartridge carrier 24 to form an articulationjoint 27 that enables the carrier 24 to pivot about an articulation axis“AA-AA” that is transverse to a longitudinal tool axis “LA-LA”.Referring to FIG. 3, mounting assembly 28 may include, for example,upper and lower mounting portions 30 and 32. Each mounting portion 30,32 may include a threaded bore 34 on each side thereof that isdimensioned to receive threaded bolts (not shown) for securing theproximal end of carrier 24 thereto. A pair of centrally located pivotmembers 36 may extend between upper and lower mounting portions via apair of coupling members 38 which engage a distal end of a housingportion 40. Coupling members 38 may each include an interlockingproximal portion 39 that is configured to be received in grooves 42 thatare formed in the proximal end of housing portion 40 to retain mountingassembly 30 and housing portion 40 in a longitudinally fixed position.

As can be further seen in FIG. 3, housing portion 40 of loading unit 20may include an upper housing half 44 and a lower housing half 46 thatare each configured to be received within an outer casing 50. Theproximal end of housing half 44 may include engagement nubs 48 forreleasably engaging a distal end of an elongated shaft assembly 16. Thenubs 48 may form a “bayonet-type” coupling with the distal end of theelongated shaft assembly 16, for example. Various coupling arrangementsare described in greater detail herein. Housing halves 44, 46 may definea channel 47 for slidably receiving an axially-movable drive beam 60. Asecond articulation link 70 may be dimensioned to be slidably positionedwithin a slot 72 formed between housing halves 44, 46. A pair of“blowout” plates 74 may be positioned adjacent the distal end of housingportion 40 adjacent the distal end of axial drive beam 60 to preventoutward bulging of the drive beam 60 during articulation of carrier 24.

The drive beam 60 may include a distal working head 62 and a proximalengagement section 64. Drive beam 60 may be constructed from a singlesheet of material or, preferably, from multiple stacked sheets.Engagement section 64 may include a pair of engagement fingers which aredimensioned and configured to mountingly engage a pair of correspondingretention slots formed in drive member 66. Drive member 66 may include aproximal porthole 67 that is configured to receive a distal end of afiring rod when the proximal end of loading unit 20 is engaged withelongated shaft assembly of the surgical instrument 10. The distalworking head 62 may have a tissue cutting portion 63 formed thereon. Thedistal working head 62 may further include a pair of pins 65 that areconfigured to engage the anvil assembly 22 to pivot it to a closedposition to clamp tissue between the anvil 22 and the staple cartridge26 as the distal working head 62 is distally driven through the staplecartridge 26. A tissue cutting portion 63 on the distal working head 62serves to cut through the clamped tissue as the surgical staples (notshown) that are supported in the staple cartridge 26 are driven intoforming contact with the anvil 22 in a known manner. For example, thedistal working head 62 is configured to axially engage and advance asled (not shown) that is movably supported in the staple cartridge 26.As the sled is driven in the distal direction by the drive member 66,the sled contacts pushers (not shown) that are associated with thestaples and causes the pushers to drive the staples out of the cartridge26 into forming engagement with anvil 22 on the loading unit 20.

As can be seen in FIG. 1, the surgical instrument 10 includes a motor100 that is configured to generate rotary actuation motions that may beemployed, for example, to apply firing motions to the loading unit 20 aswill be discussed in further detail below. In at least one form, forexample, the motor 100 is configured to apply rotary actuation motionsto a firing member assembly, generally designated as 82. In onearrangement, for example, the firing member assembly 82 includes a drivetube 102 that is rotatably supported within the housing 12 and has aninternal thread (not shown) formed therein. A proximal threaded portionof a firing rod 104 is supported in threaded engagement with the drivetube 102 such that rotation of the drive tube 102 results in the axialmovement of the firing rod 104. The firing rod 104 may threadablyinterface with the interior of the drive beam 60 in the loading unit 20.As discussed in further detail in the aforementioned incorporated Zemlok'763 and Zemlok '344, rotation of drive tube 102 in a first direction(e.g., counter-clockwise) causes the firing rod 104 to advance the drivemember 60 in the distal direction. Initial advancement of the drivemember 60 in the distal direction within the loading unit 20 causes theanvil 22 to pivot toward the staple cartridge 26. The anvil 22 isactuated by pins 65 on the drive member 60 which serve to cam the anvil22 to a closed position as the drive member 60 is initially driven inthe distal direction “DD”. Additional distal translation of firing rod104 and ultimately of the drive member 60 through the loading unit 20causes the staples to be driven into forming contact with the stapleforming undersurface on the anvil 22.

As can be further seen in FIG. 1, the surgical instrument 10 may includean articulation system generally designated as 109. However, surgicalinstrument 10 may include various other articulation system arrangementsdisclosed in detail herein. In at least one form, the articulationsystem 109 may include an articulation mechanism 110 that includes anarticulation motor 112 and a manual articulation knob 114. Thearticulation motor 112 may be actuated by a powered articulation switch116 or by pivoting the manual articulation knob 114. Actuation of thearticulation motor 112 serves to rotate an articulation gear 118 of thearticulation mechanism 110. Actuation of articulation mechanism 110 maycause the end effector (e.g., the cartridge/anvil portion of the loadingunit 20) to move from its first position, wherein its axis issubstantially aligned with longitudinal tool axis “LA-LA” of theelongated shaft assembly 16 to a position in which the axis of the endeffector is disposed at an angle relative to the longitudinal tool axis“LA-LA” of the elongated shaft assembly about, for example, articulationaxis “AA-AA”. Further discussion regarding various aspects of thearticulation mechanism 110 may be found in Zemlok '763 which waspreviously incorporated by reference herein in its entirety. Inaddition, U.S. Pat. No. 7,431,188 entitled SURGICAL STAPLING APPARATUSWITH POWERED ARTICULATION, the entire disclosure of which is herebyincorporated by reference herein, discloses motor-powered articulatableend effectors which may be employed in connection with surgicalinstrument 10.

In various embodiments, the surgical instrument can include at least onemotor, which can apply firing motions to the loading unit 20 and/orarticulation motions to the articulation system 109, as describedelsewhere in greater detail. The motor 100 may, for example, be poweredby a power source 200 of the type described in further detail in Zemlok'763. For example, the power source 200 may comprise a rechargeablebattery (e.g., lead-based, nickel-based, lithium-ion based, etc.). It isalso envisioned that the power source 200 may include at least onedisposable battery. The disposable battery may, for example, be betweenabout 9 volts and about 30 volts. However, other power sources may beemployed. FIG. 1 illustrates one example wherein the power source 200includes a plurality of battery cells 202. The number of battery cells202 employed may depend upon the current load requirements of theinstrument 10.

In certain embodiments, the surgical instrument 10 can include asecondary power source for powering the at least one motor of thesurgical instrument 10. For example, referring now to FIG. 129, thesurgical instrument 10 may include a power system 2000 which can beconfigured to provide energy for operation of the surgical instrument10. The power system 2000, as illustrated in FIG. 129, can be placed,for example, in the handle portion 14 of the housing 12 and may includea primary power source 2002 and a secondary or backup power source 2004.The primary power source 2002 can be configured to provide energy foroperation of the surgical instrument 10 during normal operation and thesecondary power source 2004 can be configured to provide energy foroperation of the surgical instrument 10, at least in a limited capacity,when the primary power source 2002 is not available to provide energyfor the operation of the surgical instrument 10, for example, when theprimary power source 2002 is depleted, and/or when disconnected from thesurgical instrument 10. For example, the secondary power source 2002 canbe configured to provide energy to restore the surgical instrument 10 toa default status in the event the primary power source 2002 is depletedand/or disconnected from the surgical instrument 10 during a surgicalprocedure.

Referring to FIG. 1, as described elsewhere in greater detail, a powersource such as, for example, the power source 200 can supply power foroperation of the surgical instrument 10. For example, the power source200 can supply power for a motor such as, for example, motor 100 tocause rotation of the drive tube 102 in a first direction and ultimatelythe axial advancement of the firing rod 104 which drives the drive beam60 distally through the loading unit 20. Alternatively, the power source200 can supply power for the motor 100 to cause rotation of the drivetube 102 in a second direction opposite the first direction andultimately the axial retraction of the firing rod 104 which can move thedrive beam 60 proximally to its starting and/or default position.Similarly, the primary power source 2002 can be configured to supplypower for the motor 100 to advance and/or retract the firing rod 104during normal operation of the surgical instrument 10. In addition, thesecondary power source 2004 can be configured to supply power needed toretract the firing rod 104 to the default position in the event theprimary power source 2002 becomes unavailable to provide the neededpower such as, for example, when the primary power source 2002 isdepleted and/or disconnected from the surgical instrument 10.

Further to the above, as described elsewhere in greater detail, thesurgical instrument 10 can be configured to record and store a varietyof information about the operation of the surgical instrument 10 duringa surgical procedure such as, for example, an articulation angle of endeffector 20 (See FIG. 2), an actuation status of the end effector 20,sensor readings, number of firings, tissue thickness, and/or position ofthe firing rod 104. In certain examples, such information can berecorded and stored in a volatile or temporary memory such as, forexample, a random access memory (RAM) unit which may require power tomaintain the stored information. During normal operation of the surgicalinstrument 10, the primary power source 2002, similar to other powersources described elsewhere in greater detail, may supply the powerneeded to maintain the stored information within the volatile ortemporary memory units of the surgical instrument 10. In addition, thesecondary power source 2004 can supply the power needed to temporarilymaintain the stored information in the event the primary power source2002 becomes unavailable to supply the needed power such as, forexample, when the primary power source 2002 is depleted and/ordisconnected from the surgical instrument 10.

In certain aspects, the surgical instrument 10 may include a controlsystem 2005 of the type and construction disclosed in Zemlok '763, whichhas been herein incorporated by reference in its entirety. Furtherdetails regarding the construction and operation of such control system2005 may be obtained from that publication. For example, the controlsystem 2005 may be configured to generate or provide information, suchas a warning or instrument state, to a user via a user interface, suchas a visual or audio display. Signals or inputs generated by the controlsystem 2005 may be, for example, in response to other signals or inputsprovided by the user, instrument components, or may be a function of oneor more measurements associated with the instrument 10. During normaloperation of the surgical instrument 10, as described elsewhere ingreater detail, a power source such as, for example, the primary powersource 2002 (See FIG. 129) can supply power needed to permit the controlsystem 2005 to perform its functions including interactions with a userthrough the user interface. In addition, the secondary power source 2004can supply, in at least a limited capacity, the power needed totemporarily interact with a user through the user interface in the eventthe primary power source 2002 becomes unavailable to supply the neededpower such as, for example, when the primary power source 2002 isdepleted and/or disconnected from the surgical instrument 10.

Referring now to FIG. 130, the power system 2000 may comprise powermanagement circuit 2006 which may be connected to the primary powersource 2002 and the secondary power source 2004. The power managementcircuit 2006 may include or may be selectively associated with asemiconductor, computer chip, or memory. The power management circuit2006 may be configured to send or receive analog or digital inputs orsignals to or from various components of the surgical instrument 10including but not limited to the control system 2005, the primary powersource 2002, and/or the secondary power source 2004. In various aspects,the power management circuit 2006 may use software that may employ oneor more algorithms to further formulate input signals to control andmonitor various components of the surgical instrument 10 including theprimary power source 2002 and/or the secondary power source 2004. Suchformulated input signals may be a function of criteria measured and/orcalculated by the power management circuit 2006 or, in some instances,provided to the power management circuit 2006 by another instrumentcomponent, a user, or a separate system in operative communication withthe power management circuit 2006.

Referring again to FIG. 129, the primary power source 2002 may compriseone or more battery cells depending on the current load needs of theinstrument 10. In various aspects, as illustrated in FIG. 129, theprimary power source 2002 may include a battery pack 2008 which mayinclude a plurality of battery cells 2010 which may be connected inseries with each other, for example. The battery pack 2008 can bereplaceable. In other words, the battery pack 2008 can be disconnectedand removed from the surgical instrument 10 and replaced with anothersimilar battery pack. In certain aspects, the primary power source 2002may comprise a rechargeable battery (e.g., lead-based, nickel-based,lithium-ion based, etc.). The battery cells 2008 may be, for example,3-volt lithium battery cells, such as CR 123A battery cells, although,for example, in other embodiments, different types of battery cellscould be used such as battery cells with different voltage levels and/ordifferent chemistries, for example. A user may disconnect and remove adepleted or used battery pack 2008 from the surgical instrument 10 andconnect a charged battery pack 2008 to power the surgical instrument 10.The depleted battery pack 2008 can then be charged and reused. It isalso envisioned that the primary power source 2002 may include at leastone disposable battery. In various aspects, the disposable battery maybe between about 9 volts and about 30 volts, for example. A user maydisconnect and remove a depleted disposable battery pack 2008 andconnect a new disposable battery pack 2008 to power the surgicalinstrument 10.

As described above, the battery pack 2008 may include rechargeablebattery cells and can be removably placed within the handle portion 14of the housing 12, for example. In such circumstances, the battery pack2008 can be charged using a charger base. For example, as illustrated inFIG. 131, charger base 2012 can be connected to battery pack 2008 byremoving the battery pack 2008 from its location in the handle portion14 and connecting it to the charger base 2012. As shown in FIG. 131, thecharger base 2012 may comprise a power source 2014 for charging thebattery pack 2008. The power source 2014 of the charger base 2012 maybe, for example, a battery (or a number of series-connected batteries),or an AC/DC converter that converters AC power, such as from electricalpower mains, to DC, or any other suitable power source for charging thebattery pack 2008. The charger base 2012 may also comprise indicatordevices, such as LEDs, a LCD display, etc., to show the charge status ofthe battery pack 2008.

In addition, as shown in FIG. 131, the charger base 2012 may compriseone or more processors 2016, one or more memory units 2018, and i/ointerfaces 2020, 2022, for example. Through the first i/o interface2020, the charger base 2012 may communicate with the power pack 2008(via a power pack's i/o interface) to allow, for example, data stored ina memory of the power pack 2008 to be downloaded to the memory 2020 ofthe charger base 2012. In various circumstances, the downloaded data canthen be downloaded to another computer device via the second i/ointerface 2022 for evaluation and analysis, such as by the hospitalsystem in which the operation involving the instrument 10 is performed,by the office of the surgeon, by the distributor of the instrument, bythe manufacturer of the instrument, etc.

The charger base 2012 may also comprise a charge meter 2024 formeasuring the charge across the battery cells of the battery pack 2008.The charge meter 2024 may be in communication with the processor 2016,so that the processor 2016 can determine in real-time the suitability ofthe battery pack 2008 for use to ensure that the battery would performas expected.

Referring again to FIG. 129, the secondary power source 2004 maycomprise one or more battery cells 2026 which can be disposed, forexample, within the handle portion 14. The battery cell 2026 can berechargeable (e.g., lead-based, nickel-based, lithium-ion based, etc.).For example, the battery cell 2026 may be a 3-volt lithium battery cell,such as CR 123A battery cell. In addition, the battery cell 2026 can beconfigured to be recharged without being removed from the instrument 10.For example, the primary power source 2002 can be utilized to charge thebattery cell 2026 when the primary power source 2002 is connected to theinstrument 10.

Referring to FIG. 132, an exemplary embodiment of the power managementcircuit 2006 is illustrated. Among other things, the power managementcircuit 2006 can be configured to monitor electrical parametersassociated with the operation of the primary power source 2002 and/orthe secondary power source 2004. For example, the power managementcircuit 2006 can be configured to monitor power levels in the primarypower source 2002 and/or the secondary power source 2004. The powermanagement circuit 2006, as shown in FIG. 132, may comprise a chargemeter 2028 which may be configured to measure the charge across theprimary power source 2002 and/or the secondary power source 2004. Thepower management circuit 2006 also may comprise a non-volatile memory2030, such as flash or ROM memory, for example, and one or moreprocessors 2032. The processor 2032 may be connected to and may controlthe memory 2030. In addition, the processor 2032 may be connected to thecharge meter 2028 to read the readings of and otherwise control thecharge meter 2028. Additionally, the processor 2032 may control outputdevices of the power management circuit 2006 such as, for example, LEDs.

The reader will appreciate that charge meters 2024 and/or 2028 may beconfigured to measure voltage, charge, resistance and/or current. Incertain examples, the charge meters 2024 and/or 2028 may comprise abattery capacity measurement circuit which may be configured to measurestate of voltage under a predetermined load.

Further to the above, the processor 2032 can store information about theprimary power source 2002 and/or the secondary power source 2004 in thememory 2030. The information may include among other things total chargeavailable, number of uses, and/or performance. Additionally, theinformation stored in the memory 2030 may comprise ID values for theprimary power source 2002 that the power management circuit 2006 mayread and store. Such IDs may be, for example, RFIDs that the powermanagement circuit 2006 read via a RFID transponder 2034. The RFIDtransponder 2034 may read RFIDs from the power sources that include RFIDtags. The ID values may be read, stored in the memory 2030, and comparedby the processor 2032 to a list of acceptable ID values stored in thememory 2030 or another store associated with the power managementcircuit 2006, to determine, for example, if the removable/replaceableprimary power source 2002 associated with the read ID value is authenticand/or proper. In such circumstances, if the processor 2032 determinesthat the removable/replaceable component associated with the read IDvalue is not authentic, the power management circuit 2006 may beconfigured to prevent use of the instrument 10, such as by opening aswitch (not shown) that would prevent power from being delivered to theinstrument 10. Various parameters that the processor 2032 may evaluateto determine whether the component is authentic and/or proper includedate code, component model/type, manufacturer, regional information,and/or previous error codes, for example.

Further to the above, the power management circuit 2006 may alsocomprise an i/o interface 2036 for communicating with another device,for example a computer, to permit the data stored in the memory 2030 tobe downloaded to the other device for evaluation and analysis, such asby the hospital system in which the operation involving the instrument10 is performed, by the office of the surgeon, by the distributor of theinstrument, and/or by the manufacturer of the instrument, for example.The i/o interface 2036 may be, for example, a wired or wirelessinterface.

Referring to the block diagram illustrated in FIG. 133, the powermanagement circuit 2006 may selectively transmit power to the surgicalinstrument 10 from the primary power source 2002 and the secondary powersource 2004. For example, the processor 2032 may be programmed to permitpower to be transmitted to the instrument 10 from the primary powersource 2002 when the primary power source 2002 is available to power theinstrument 10 and from the secondary power source 2004 when the primarypower source 2002 is not available to power the instrument 10.

During normal operation of the instrument 10, the processor 2032 upondetection and authentication of the primary battery source 2002, asdescribed above, may permit the primary power source 2002 to power theinstrument 10. The primary power source 2002 may continue to power theinstrument 10 until the primary power source 2002 reaches or fallsbellow a predetermined minimum charge level such as, for example, whenthe primary power source 2002 is disconnected and/or depleted. The powermanagement circuit 2006 could be employed to determine when the primarypower source 2002 reaches or falls bellow the predetermined minimumcharge level. For example, the processor 2032 can be configured toemploy the charge meter 2028 or another similar charge meter to monitorthe charge level of the primary power source 2002 and detect when thecharge level reaches or falls below a predetermined minimum level thatcan be stored in the memory 2030 of the power management circuit 2006.At such point, the processor 2032 may alert the user to replace theprimary power source 2002. The power management circuit 2006 may includean indicator, such as one or more LEDs, an LCD display, for example,that is activated to alert a user of the instrument 10 replace theprimary power source 2002. Furthermore, the processor 2032 may beconfigured to switch the powering of the instrument 10 from the primarypower source 2002 to the secondary power source 2004 upon detecting thatthe charge level of the primary power source 2002 has reached or fallenbelow the predetermined minimum level. The reader will appreciate thatadditional indicators can be utilized to provide a user with additionalfeedback. For example, an indicator can be utilized to alert the userthat instrument 10 is switching from the primary power source 2002 tothe secondary power source 2004, and vise versa.

Further to the above, the processor 2032 may be programmed to permit theprimary power source 2002 to charge the secondary power source 2004 whenthe primary power source 2002 is connected to the surgical instrument10. In certain examples, the secondary power source 2004 may remain idleonce fully charged by the primary power source 2002 to a predeterminedmaximum power level for as long as the primary power source 2002 remainsavailable to power the instrument 10. In addition, the power managementcircuit 2006 could be employed to determine when the secondary powersource 2004 is sufficiently charged. For example, the processor 2032 canbe configured to employ the charge meter 2028 to monitor the chargelevel of the secondary power source 2004 until the charge level reachesa predetermined maximum level that can be stored in the memory 2030 ofthe power management circuit 2006 at which point the processor 2032 maystop the primary power source 2002 from charging the secondary powersource 2004. The power management circuit 2006 may include an indicator,such as one or more LEDs, an LCD display, etc., that can be activated toalert a user of the instrument 10 when the secondary power source 2004is sufficiently charged.

Referring again to FIG. 129, the primary power source 2002 can be housedwithin a chamber 2038 of the handle portion 14 of the instrument 10. Toreplace the primary power source 2002, an outer shell of the handleportion 14 can be removed to expose the chamber 2038. In certainexamples, a trigger or a switch can be associated with the outer shellof the handle portion 14 such that attempting to remove the outer shellof the handle portion 14 may be understood by the processor 2032 as atriggering event to switch from the primary power source 2002 to thesecondary power source 2004.

Upon replacing the primary power source 2002 of the surgical instrument10 with a new primary power source 2002, the power management circuit2006 may check the authenticity of new primary power source 2002, asdescribed above, and upon confirming such authenticity, the powermanagement circuit 2006 may permit the new primary power source 2002 totransmit power to the instrument 10. In addition, the primary powersource 2002 may charge the secondary power source 2004, as describedabove.

Surgical end effectors, such as loading unit 20 (FIGS. 2 and 3), forexample, can be operably coupled to the elongated shaft assembly 16 ofthe powered surgical instrument 10 (FIG. 1). For example, referring nowto FIGS. 38-58, a surgical end effector, such as disposable loading unit(DLU) 5502, for example, can be releasably attached to a surgicalinstrument, such as powered surgical instrument 10 (FIG. 1), forexample. In various embodiments, the surgical instrument can include ashaft 5520, which can engage the DLU 5502, for example. In variousembodiments, a collar, such as rotatable collar 5580, for example, canreleasably lock the DLU 5502 relative to the shaft 5520. Furthermore, invarious embodiments, rotation of the collar 5580 can facilitateattachment and/or alignment of a firing assembly and/or an articulationassembly, as described herein.

In various embodiments, the DLU 5502 can include a distal attachmentportion 5504 and the shaft 5520 can include an outer tube 5554 and aproximal attachment portion 5522. The distal attachment portion 5504 ofthe DLU 5502 can receive the proximal attachment portion 5522 of theshaft 5520 when the DLU 5502 is secured to the shaft 5520 (FIG. 39).Furthermore, the rotatable collar 5580 can be positioned around theproximal attachment portion 5522 of the shaft 5520, such that the distalattachment portion 5504 of the DLU 5502 can also be positioned withinthe rotatable collar 5580. The rotatable collar 5580 can be secured tothe shaft 5502 and/or the proximal attachment portion 5504, and, incertain embodiments, can be rotatably fixed to the proximal attachmentportion 5504 of the shaft 5502, for example. In certain embodiments, aproximal attachment portion of the shaft 5520 can receive a distalattachment portion of the DLU 5502 when the DLU 5502 is secured to theshaft 5520. Furthermore, in certain embodiments, a collar 5580 can berotatably fixed to the DLU 5502.

Referring still to FIGS. 38-58, as the DLU 5502 moves between anon-attached position and an attached position relative to the shaft5520 of the surgical instrument, the DLU 5502 can translate along alongitudinal axis defined by the shaft 5520. The distal attachmentportion 5504 of the DLU 5502 can be inserted into the proximalattachment portion 5522 of the shaft 5520 as the DLU 5502 moves from thenon-attached position to the attached position. For example, the DLU5502 can translate in direction A (FIG. 39) when the DLU 5502 is movedbetween the non-attached position and the attached position. In certainembodiments, a groove-and-slot engagement between the distal attachmentportion 5504 and the proximal attachment portion 5522 can guide the DLU5502 along the longitudinal axis defined by the shaft 5520. Referringprimarily to FIG. 42, the distal attachment portion 5504 can include aguide rail 5514. Furthermore, referring primarily to FIG. 44, theproximal attachment portion 5522 can include a guide slot 5534. Theguide slot 5534 can be dimensioned and structured to receive and guidethe guide rail 5514 as the proximal attachment portion 5504 of the DLU5502 is inserted into the distal attachment portion 5522 of the shaft5520. For example, the guide slot 5534 can comprise a longitudinal slot,and the guide rail 5514 can comprise a longitudinal ridge, for example.In certain embodiments, the guide slot 5534 and guide rail 5514 canprevent twisting and/or rotating of the DLU 5502 relative to thelongitudinal axis defined by the shaft 5520.

Referring primarily to FIG. 38, the distal attachment portion 5504 caninclude a first alignment indicia 5510, such as a first arrow, forexample, and the shaft 5520 and/or the collar 5580 can include a secondalignment indicia 5590, such as a second arrow, for example. Alignmentof the first and second alignment indicia 5510, 5590 can align the guiderail 5514 and the guide slot 5534, which can facilitate attachment ofthe distal attachment portion 5504 to the proximal attachment portion5522. As described herein, translation of the DLU 5502 along alongitudinal path toward the shaft 5520 can releasably lock the DLU 5502relative to the shaft 5520. In such embodiments, rotation of the DLU5502 relative to the shaft 5520 may not be required to attach the DLU5502 relative to the shaft 5520. In fact, rotation the DLU 5502 relativeto the shaft 5520 can be restrained and/or prevented by agroove-and-slot engagement between the proximal attachment portion 5522and the distal attachment portion 5504, as described herein. In variousembodiments, the collar 5580 can rotate relative to the DLU 5502 and/orthe shaft 5520 to releasably lock the DLU 5502 to the shaft 5520. Forexample, as described herein, the collar 5580 can rotate from an initialorientation (FIG. 53) toward a secondary orientation (FIG. 54) and thenreturn toward the initial orientation (FIG. 57) to lock the DLU 5502 tothe shaft 5520.

Referring primarily to FIGS. 42 and 43, the proximal portion 5504 of theDLU 5502 can include a rotation key or rib 5506. As the DLU 5502 ismoved in direction A (FIG. 39) between a non-attached position (FIG. 38)and an attached position (FIG. 39), the rotation key 5506 can affectrotation of the collar 5580. For example, the rotation key 5506 canrotate and/or bias the collar 5580 in direction B (FIG. 39) from theinitial orientation to the secondary orientation. The distal attachmentportion 5504 can be inserted into the proximal attachment portion 5522when the collar 5580 is biased into the secondary orientation.Furthermore, when the distal attachment portion 5504 is fully insertedinto the proximal attachment portion 5522, the rotation key 5506 canpermit the collar 5580 to rotate in direction C (FIG. 39) from thesecondary orientation toward the initial orientation. Direction C can beopposite to direction B, for example. As described herein, when thecollar 5580 returns to the initial orientation, the collar 5580 can lockthe distal attachment portion 5504 relative to the proximal attachmentportion 5522. Referring still to FIGS. 42 and 43, the rotation key 5506can include a rotation ramp 5508 at the proximal end thereof. Therotation ramp 5508 can engage an element of the shaft 5520 to effectrotation of the rotation collar 5580, for example.

In various embodiments, the rotation ramp 5508 can affect rotation of afiring shaft 5540 positioned within the shaft 5520. For example,referring primarily to FIGS. 47-50, the firing shaft 5540 can include afiring shaft rotator 5544 which can extend radially outward from thefiring shaft 5540. The rotation ramp 5508 of the rotation key 5506 canengage the firing shaft rotator 5544 when the DLU 5502 is inserted intothe shaft 5520. In various embodiments, the rotation ramp 5508 canrotate the firing shaft rotator 5544, which can rotate the firing shaft5540. For example, the firing shaft 5540 and the firing shaft rotator5544 can rotate in direction B (FIG. 54) between a first orientation(FIG. 53) and a second orientation (FIG. 54). Referring still to FIGS.47-50, the firing shaft 5540 can be engaged with the rotatable collar5580. For example, the rotatable collar 5580 can include a rotatorgroove 5584, which can be structured and dimensioned to receive and/orhold the firing shaft rotator 5544. The firing shaft rotator 5544 can beheld by the rotator groove 5584, such that the rotation of the firingshaft rotator 5544 rotates the rotatable collar 5580. In suchembodiments, insertion of the DLU 5502 into the shaft 5520, can affectrotation of the rotatable collar 5580 in direction B (FIG. 54) viarotation of the firing shaft rotator 5544 in direction B, for example.

Referring primarily to FIGS. 44 and 45, the proximal attachment portion5522 can include a rotation key slot 5524, which can receive therotation key 5506 when the distal attachment portion 5504 is insertedinto the proximal attachment portion 5522. In various embodiments, therotation key slot 5524 can include a clearance notch 5526 for receivingthe firing shaft rotator 5544. For example, the rotation ramp 5508 atthe proximal end of the rotation key 5506 can rotate the firing shaftrotator 5544 to the second orientation and into the clearance notch 5526(FIG. 54). The rotation key 5506 can continue to move along the rotationkey slot 5524 as the DLU 5502 is inserted into the shaft 5520.Furthermore, when the distal end 5509 of the rotation key 5506 movespast the firing shaft rotator 5544, the firing shaft rotator 5544 canrotate back toward the first orientation (FIG. 58), which cancorresponding rotate the rotatable collar 5580 back toward the initialorientation thereof.

In various embodiments, the rotatable collar 5580 can be biased into theinitial orientation relative to the shaft 5520 and/or the proximalattachment portion 5522. For example, a spring 5592 can bias the lockcollar 5580 into the initial orientation. The spring 5592 can include aproximal end 5594 that can be secured relative to the shaft 5520, and adistal end 5596 that can be secured relative to the collar 5580. Forexample, the proximal end 5594 of the spring 5592 can be retained in aproximal spring slot 5538 (FIG. 51) of the shaft 5520, and the distalend 5596 of the spring 5592 can be retained in a distal spring slot 5588(FIG. 46) of the rotatable collar 5580, for example. In suchembodiments, rotation of the collar 5580 can displace the distal end5596 of the spring 5592 relative to the proximal end 5594 of the spring5592, which can generate a torsional force. Accordingly, the collar 5580can resist rotation from the initial orientation to the secondaryorientation, and, when the collar is rotated to the secondaryorientation, the spring 5592 can bias the collar 5580 back toward theinitial orientation. Because the firing shaft rotator 5544 is engagedwith the collar 5580, the spring 5592 can also bias the firing shaft5540 toward the first orientation thereof.

In various embodiments, the rotatable collar 5580 can include a lockingdetent 5582 that releasably locks the DLU 5502 to the shaft 5520.Referring primarily to FIG. 46, the locking detent 5582 can extendradially inward from the inner perimeter of the rotatable collar 5580.In various embodiments, the locking detent 5582 can extend into a detentslot 5536 (FIG. 44) in the proximal attachment portion 5522. Referringprimarily to FIG. 44, the detent slot 5536 can form a notch in the guideslot 5534. In various embodiments, the detent slot 5536 can extend fromthe guide slot 5534, and can be perpendicular or substantiallyperpendicular to the guide slot 5534, for example. Further, the lockingdetent 5582 can move along the detent slot 5536 when the rotatablecollar 5580 rotates between the initial orientation and the secondaryorientation relative to the shaft 5520.

In various embodiments, the locking detent 5582 can engage the distalattachment portion 5504 of the DLU 5502 to lock the DLU 5502 relative tothe shaft 5520. For example, referring again to FIG. 42, the distalattachment portion 5504 can include the guide rail 5514, which can havea lock notch 5516 defined therein. The lock notch 5516 can be structuredand dimensioned to receive the locking detent 5582 of the rotatablecollar 5580 when the DLU 5502 is fully inserted into the proximalattachment portion 5522. For example, when the distal attachment portion5504 is fully inserted into the proximal attachment portion 5522, thelock notch 5516 of the distal attachment portion 5504 can be alignedwith the detent slot 5536 of the proximal attachment portion 5522.Accordingly, the locking detent 5582 can slide along the detent slot5536 in the proximal attachment portion 5522 and into the lock notch5516 in the distal attachment portion. Furthermore, the locking detent5582 can be biased toward engagement with the lock notch 5516 by thetorsion spring 5592. For example, after the firing shaft rotator 5544clears the distal end 5509 of the rotation key 5506, the firing shaft5540 can be biased back toward the first orientation and the rotatablecollar 5580 can be biased back toward the initial orientation by thetorsion spring 5592. Furthermore, when the collar 5580 is rotated fromthe secondary orientation back to the initial orientation, the lockingdetent 5582 thereof can be aligned and engaged with the lock notch 5516in the guide rail 5514.

In various embodiments, rotation of the collar 5580 can facilitateattachment and/or alignment of a firing assembly. For example, thefiring shaft 5540 can extend between a proximal end 5546 and a distalend 5542. The proximal end 5546 can have a rotation joint, which canpermit rotation of the firing shaft 5540 between the first configurationand the second configuration. Furthermore, the distal end 5542 can havea coupler for attaching a cutting element of the DLU 5502. Rotation ofthe firing shaft 5540 can facilitate attachment of the cutting element.For example, as the coupler at the distal end 5542 of the firing shaft5540 rotates, the coupler can engage and connect to the cutting elementin the DLU 5502. In certain embodiments, the coupler can include abayonet mount, which can engage a corresponding bayonet receiver of thecutting element in the DLU 5502. Referring primarily to FIGS. 40 and 41,the firing assembly can further include a sleeve 5550 positioned aroundthe firing shaft 5540 between the proximal end 5546 and the distal end5542, for example.

In various embodiments, when the firing shaft 5540 rotates within theshaft 5520, the firing shaft 5540 can rotate into alignment with afiring shaft slot 5518 in the DLU 5502. For example, the firing shaftrotator 5544 can be aligned with the firing shaft slot 5518 when the DLU5502 is fully inserted and attached to the shaft 5520. However, invarious embodiments, when the DLU 5502 is only partially inserted intothe shaft 5520, the firing shaft rotator 5544 can be rotated, via therotation key 5506, out of alignment with the firing shaft slot 5518. Inother words, the firing shaft rotator 5544 can be aligned with thefiring shaft slot 5514 when the firing shaft 5540 is in the firstorientation, and can be misaligned with the firing shaft slot 5514 whenthe firing shaft 5540 rotates toward the second orientation. In suchembodiments, when the DLU 5502 is only partially inserted into the shaft5520 and/or before the DLU 5502 is releasably locked to the shaft 5520by the rotatable collar 5580, the firing path of the firing shaftrotator 5544 can be blocked by the distal attachment portion 5504.Integration of the firing shaft 5540 and the collar 5580 can ensure theDLU 5502 is securely attached to the shaft 5520 before the firing shaft5540 can fire and/or advance. For example, the surgical instrument maybe unable to fire until the cutting element in the DLU 5502 is coupledto the firing shaft 5540, and/or until the firing shaft 5540 is properlyaligned within the shaft 5520, for example.

In certain embodiments, rotation of the collar 5580 can facilitateattachment and/or alignment of an articulation assembly 5559. Referringprimarily to FIGS. 40 and 41, the articulation assembly 5559 can includea proximal articulation bar 5560, a distal articulation bar 5562, and anarticulation connector 5566. Furthermore, the shaft 5520 can include aproximal articulation bar slot 5528, and the DLU 5502 can include adistal articulation bar slot 5512, for example. In certain embodiments,the proximal articulation bar 5560 can be aligned with the proximalarticulation bar slot 5528, and the distal articulation bar 5562 can bealigned with the distal articulation bar slot 5512. Referring now toFIG. 46, the articulation connector 5566 can be housed in the rotatablecollar 5580. For example, the rotatable collar 5580 can include anarticulation connector slot 5586, and the articulation connector 5566can be moveably positioned therein.

In various embodiments, referring again to FIGS. 40 and 41, the proximalarticulation bar 5560 can have a proximal notch 5572, and the distalarticulation bar 5562 can have a distal notch 5574. Furthermore, thearticulation connector 5566 can include a proximal articulation lug 5568and a distal articulation lug 5572. The proximal articulation lug 5568can be retained in the proximal notch 5572 of the proximal articulationbar 5560. In certain embodiments, the distal articulation lug 5570 canoperably engage the distal notch 5574 of the distal articulation bar5562. As described herein, the rotatable collar 5580 can rotate betweenthe initial configuration and the secondary configuration. As the collar5580 rotates, the articulation connector 5566 housed therein can alsorotate relative to the longitudinal axis defined by the shaft 5520. Invarious embodiments, the proximal articulation lug 5568 of thearticulation connector 5566 can remain positioned in the proximal notch5572 of the proximal articulation bar 5560 as the articulation connector5566 rotates. Furthermore, the distal articulation lug 5570 of thearticulation connector 5566 can move into engagement with the distalnotch 5574 of the distal articulation bar 5562 as the articulationconnector 5566 rotates with the collar 5580 from the secondaryorientation toward the initial orientation. For example, when the DLU5502 is fully inserted into the shaft 5508, the distal notch 5574 of thedistal articulation bar 5562 can be aligned with the distal articulationlug 5568 of the articulation connector 5566. In such embodiments, whenthe rotatable collar 5580 rotates back to the initial configuration, thedistal articulation lug 5568 can slide into the distal notch 5574 of thedistal articulation bar 5562. When the distal articulation lug 5568 ispositioned in the distal notch 5574, the articulation assembly 5559 canbe fully assembled.

Referring primarily to FIG. 45, in various embodiments, the proximalarticulation bar slot 5528 can include a first clearance 5530 and asecond clearance 5532. The proximal and distal articulation lugs 5568,5570 of the articulation connector 5566 can extend into the first andsecond clearances 5530, 5532, respectively. In certain embodiments, thefirst and second clearances 5530, 5532 can provide a space for theproximal and distal articulation lugs 5568, 5570 to move as the collar5580 rotates and/or as the articulation assembly 5559 articulates, forexample.

Referring now to FIGS. 51-58, to connect the DLU 5502 to the shaft 5520of the surgical instrument, a user can align the alignment indicia 5510of the DLU 5502 with the alignment indicia 5590 of the shaft 5520 and/orthe collar 5580 (FIG. 51). While maintaining alignment of the alignmentindicia 5510, 5590, the user can move the DLU 5502 relative to the shaft5520 along the longitudinal axis defined by the shaft 5520. The user canmove the DLU 5502 along a straight or substantially straight path, and,in various embodiments, need not rotate the DLU relative to the shaft5520, for example. Referring primarily to FIG. 53, the DLU 5502 cancontinue to translate relative to the shaft 5520, and the guide rail5514 of the distal attachment portion 5504 can fit into the guide slot5534 (FIG. 44) in the proximal attachment portion 5522 of the shaft5520. As the distal attachment portion 5504 moves into the proximalattachment portion 5522, the guide slot 5534 can guide the guide rail5514, and can maintain alignment of the alignment indicia 5510, 5590,for example. In other words, the guide slot 5534 and the guide rail 5514can prevent rotation of the DLU 5502 relative to the longitudinal axisof the shaft 5520. Referring primarily to FIG. 52, the proximalarticulation lug 5568 of the articulation connector 5522 can extend intothe first clearance 5530 and can be positioned in the proximal notch5572 of the proximal articulation bar 5562, and the distal articulationlug 5570 of the articulation connector 5522 can extend through thesecond clearance 5532, for example.

Referring primarily to FIG. 54, as the distal attachment portion 5504 isinserted into the proximal attachment portion 5522, the rotation keyramp 5508 of the rotation key 5506 can abut the firing shaft rotator5544. The rotation key ramp 5508 can guide and/or direct the firingshaft rotator 5544 into the clearance notch 5526 extending from therotation key slot 5524. Furthermore, as the firing shaft rotator 5544moves into the clearance notch 5526, the firing shaft 5540 can rotate inthe direction B. The firing shaft 5540 can rotate from the firstorientation to the second orientation. Such rotation of the firing shaft5540 can facilitate attachment of the distal end 5542 of the firingshaft 5540 with a cutting element in the DLU 5502. Furthermore, rotationof the firing shaft rotator 5544 can rotate the collar 5580 in thedirection B via the engagement between the firing shaft rotator 5544 andthe firing shaft rotator groove 5584 (FIG. 46) in the collar 5580. Thecollar 5580 can rotate from the initial orientation to the secondaryorientation, for example. Additionally, the locking detent 5582 can movealong the detent slot 5536 in the shaft 5520 as the collar 5580 rotates.Additionally, rotation of the collar 5580 can rotate the distal end 5596of the spring 5592 because the distal end 5596 of the spring 5592 can beretained in the distal spring slot 5588 (FIG. 46) in the collar 5580.Displacement of the distal end 5596 relative to the proximal end 5594can generate a torsional springback force, which can bias the collar5580 from the secondary orientation toward the initial orientation, forexample, and can bias the firing shaft 5540 from the second orientationtoward the first orientation, for example.

Referring primarily to FIG. 55, as the collar 5580 rotates toward thesecondary orientation, the proximal articulation lug 5568 can remainengaged with the proximal notch 5572 in the proximal articulation bar5560. Furthermore, the distal articulation lug 5570 can rotate such thatthe distal articulation lug 5570 provides a clearance for the distalarticulation bar 5562 of the DLU 5502. Referring to FIG. 56, the DLU5502 can be fully inserted into the shaft 5520 when the collar 5580 andthe articulation connector 5566 positioned therein are rotated to thesecondary orientation. In various embodiments, the distal articulationbar 5562 can clear the distal articulation lug 5570 of the articulationconnector 5566 when the articulation connector 5566 is rotated to thesecondary orientation. Furthermore, the distal articulation lug 5570 canbe rotatably aligned with the distal notch 5574 in the articulationconnector 5566. Referring still to FIG. 56, when the DLU 5502 is fullyinserted into the shaft 5520, the firing rod rotator 5544 can clear thedistal end 5509 of the rotation key 5506.

Referring now to the FIG. 57, the firing shaft rotator 5544 can rotatein the direction C when the distal end 5509 of the rotation key 5506passes the firing shaft rotator 5544. For example, the firing shaftrotator 5544 can rotate in direction C from the second orientationtoward the first orientation. Furthermore, rotation of the firing shaftrotator 5544 can affect rotation of the collar 5580 in the direction Cfrom the secondary orientation toward the initial orientation. Invarious embodiments, the spring 5592 can bias the firing rod 5540 towardthe first orientation thereof and the collar 5580 toward the initialorientation thereof. For example, the firing shaft rotator 5544 can bepositioned in the firing shaft rotator groove 5584 (FIG. 46) in thecollar 5580 such that rotation of the firing shaft rotator 5544 rotatesthe collar 5580. Due to the alignment of the distal articulation lug5570 of the articulation connector 5566 and the distal notch 5574 of thedistal articulation bar 5562, the articulation connector 5566 can rotateas the collar 5580 rotates, and the distal articulation lug 5570 canrotate into engagement with the distal notch 5574. The articulationassembly 5559 can be assembled when the distal articulation lug 5570engages the distal notch 5574. Furthermore, as the firing shaft rotator5544 rotates in direction C, the distal end 5542 of the firing shaft5540 can rotate in direction C, which can facilitate attachment of acutting element in the DLU 5502 to the distal end 5542 of the firingshaft 5540.

Referring now to FIG. 58, rotation of the collar 5580 can also rotatethe locking detent 5582 of the collar 5580 into the lock notch 5516 inthe guide rail 5514 of the distal attachment portion 5504. For example,when the DLU 5502 is fully inserted into the shaft 5520, the lock notch5516 can be aligned with the detent slot 5536 such that the lockingdetent 5582 can rotate through the detent slot 5536 and into the locknotch 5516. As described herein, the spring 5592 can bias the collar5580 to rotate in the direction C (FIG. 57) after the firing shaftrotator 5544 clears the distal end 5509 of the rotation key 5506.Referring still to FIG. 58, when the firing shaft rotator 5544 rotatesin direction C, the firing shaft rotator 5544 can move into alignmentwith the firing shaft slot 5518 in the DLU 5502. Alignment of the firingshaft rotator 5544 with the firing shaft slot 5518 can permit the firingshaft 5540 to be advanced distally to fire the DLU 5502, for example.

As described herein, the rotatable collar 5580 can releasably lock theDLU 5502 relative to the shaft 5520. Furthermore, rotation of the collar5580 can facilitate attachment and/or alignment of the articulationassembly 5559, as well as attachment and/or alignment of the firingshaft 5540 with a cutting element in the DLU 5502, for example.Furthermore, rotation of the collar can also unlock the DLU 5502 fromthe shaft, disconnect the articulation assembly 5559, and/or disconnectthe firing shaft 5540 from the cutting element in the DLU 5502. Forexample, when the collar 5580 is again rotated from the initialorientation toward the secondary orientation, the locking detent 5582can disengage the lock notch 5516 in the distal attachment portion 5504.Accordingly, the distal attachment portion 5504 can be withdrawn fromthe proximal attachment portion 5522 along the longitudinal axis definedby the shaft 5520, for example. In various embodiments, the DLU 5502 canbe unattached from the shaft 5520 without rotating the DLU 5502 relativeto the shaft 5520. However, the collar 5580 can rotate relative to theshaft 5520, which can disconnect the distal articulation bar 5562 fromthe articulation connector 5566 in the collar 5580, and can disconnectthe firing shaft 5540 from the cutting element in the DLU 5502, forexample.

Referring now to FIGS. 59-62, a disposable loading unit (DLU) or endeffector 5602 can be releasably attached to a shaft 5620 of a surgicalinstrument. In various embodiments, a spring or a plurality of springs,for example, can bias the DLU 5602 into a locked positioned relative tothe shaft 5620. For example, the DLU 5602 can be releasably attached tothe shaft 5620 by a bayonet mount, and a spring can rotate the DLU 5602to connect the DLU 5602 to the shaft 5620 at the bayonet connection. TheDLU 5602 can include a distal attachment portion 5604, and the shaft5620 can include a proximal attachment portion 5622, for example. Thedistal attachment portion 5604 of the DLU 5602 can receive the proximalattachment portion 5622 of the shaft 5620 when the DLU 5602 is securedto the shaft 5620. In other embodiments, a proximal attachment portionof the shaft 5620 can receive a distal attachment portion of the DLU5602 when the DLU 5602 is secured to the shaft 5620.

In various embodiments, the distal attachment portion 5604 of the DLU5602 can include a detent 5606, which can extend radially outward from aportion of the distal attachment portion 5604. Furthermore, the detent5606 can include a ramped surface 5608. As described herein, the rampedsurface 5608 of the detent 5606 can engage a spring, such as spring 5636b, for example, and can deform the spring 5636 b when the distalattachment portion 5604 is inserted into the proximal attachment portion5622. Furthermore, the detent 5606 can be held by the proximalattachment portion 5622 to releasably lock the DLU 5602 to the shaft5622. Referring primarily to FIG. 59, the proximal attachment portion5622 of the shaft 5620 can define a cavity 5624. In various embodiments,the cavity 5624 can be structured and dimensioned to receive the distalattachment portion 5604 of the DLU 5602. Furthermore, a spring 5636 a,5636 b can be positioned within the cavity 5624. For example, a firstspring 5636 a can be positioned on a first side of the cavity 5624, anda second spring 5636 b can be positioned on a second side of the cavity5624. The springs 5636 a, 5636 b can be symmetrical or non-symmetricalrelative to the cavity 5624. In various embodiments, at least a portionof a spring 5636 a, 5636 b can extend into the cavity 5624. For example,a leg 5637 of the second spring 5636 b can extend into the cavity 5624,and another leg 5637 of the second spring 5636 can be retained in theproximal attachment portion 5622, for example.

Referring still to FIG. 59, the proximal attachment portion 5622 canalso include a lock slot 5638, which can be defined in the cavity 5624and/or can be accessible via the cavity 5624, for example. The lock slot5638 can be structured and dimensioned to receive the detent 5606, forexample. In various embodiments, the lock slot 5638 can hold the detent5606 to releasably lock the DLU 5602 relative to the shaft 5620.Furthermore, in various embodiments, the proximal attachment portion5622 can include a latch 5630. The latch 5630 can be moveable between anunlatched position (FIGS. 59 and 60) and a latched position (FIGS. 61and 62). In various embodiments, the latch 5630 can be spring-loaded,and the spring 5634 can bias the latch 5630 into the latched position.For example, the latch 5630 can include a latch spring 5634, which canbias the latch 5630 toward and/or into the latched position. The latchedposition can be distal to the unlatched position, for example. Incertain embodiments, the latch 5630 can include a thumb grip and/orridges 5632 to facilitate movement of the latch 5630 from the latchedposition to the unlatched position. For example, a user can engage thethumb grip 5632 and draw the latch 5630 proximally to unlatch the latch5630.

In various embodiments, the latch 5630 can operably block or at leastpartially block the lock slot 5638. For example, when the latch 5630 isin the latched position (FIGS. 61 and 62), an arm 5635 of the latch 5630can extend over at least a portion of the lock slot 5638. The latch 5630can cover or partially cover the lock slot 5638, and can prevent and/orlimit access to the lock slot 5638. In certain embodiments, the arm 5635of the latch 5630 can prevent the detent 5606 from moving and/or slidinginto the lock slot 5638. Moreover, when the latch 5630 is in the latchedposition, the latch 5630 can engage the spring 5636 a, 5636 b. Forexample, referring to FIGS. 61 and 62, the latch 5630 can support thespring 5636 b, such that deformation of the spring 5636 b is limitedand/or prevented. Furthermore, the latch 5630 can support the spring5636 b such that the cavity 5624 cannot receive the distal attachmentportion 5604 of the DLU 5602. For example, at least a portion of thespring 5636 b can block the cavity 5624, which can prevent completeinsertion of the distal attachment portion 5604 into the proximalattachment portion 5622. In certain embodiments, the proximal attachmentportion 5622 can include a plurality of springs, which can exert arotational force on the distal attachment portion 5604 to rotate thedistal attachment portion 5604 relative to the proximal attachmentportion 5622. For example, the proximal attachment portion 5622 caninclude a pair of springs or more than three springs. In otherembodiments, a single spring in the proximal attachment portion 5622 canseek to rotate the distal attachment portion 5604 relative to theproximal attachment portion 5622. Additionally or alternatively, invarious embodiments, the distal attachment portion 5602 of the DLU 5602can include at least one spring, which can rotate the distal attachmentportion 5602 relative to the proximal attachment portion 5622, forexample.

In various embodiments, when the latch 5630 is in the unlatched position(FIGS. 59 and 60), the lock slot 5638 can be unblocked and/or lessblocked by the arm 5635 of the latch 5630. For example, the detent 5606can fit past the unlatched latch 5630 to fit into the lock slot 5638.Furthermore, the detent 5606 can be biased past the unlatched latch 5630and into the lock slot 5638, as described herein. Moreover, in variousembodiments, when the latch 5630 is in the unlatched position, the latch5630 can disengage the spring 5636 a, 5636 b. For example, the latch5630 may not protect and/or limit deformation of the spring 5636 a, 5636b when the latch 5630 is unlatched.

Referring primarily to FIG. 59, when the latch 5630 is moved and held ina proximal and/or unlatched position, for example, the spring 5636 b canbe unsupported by the latch 5630. In such embodiments, the DLU 5602 canbe moved in the direction A such that the distal attachment portion 5604is moved relative to the proximal attachment portion 5622. Referringprimarily to FIG. 60, the detent 5606 of the distal attachment portion5604 can engage the spring 5636 b, and can compress and/or deform thespring 5636 b, for example. In certain embodiments, the ramped surface5608 of the detent 5606 can slide along the spring 5636 b, and can movethe free leg 5637 of the spring 5636 b. Deformation of the spring 5636 bcan generate a springback force, which the spring 5636 b can exert onthe detent 5606. Referring now to FIG. 61, the springback force canaffect rotation of the detent 5606. For example, the detent 5606 canrotate in direction B into the lock slot 5638 defined in the cavity5624. In various embodiments, the latch spring 5634 can return the latch5630 to the unlatched position when the user releases the latch 5630.Furthermore, when the latch 5630 returns to the unlatched position, thearm 5635 of the latch 5630 can block or partially block the lock slot5638. In such embodiments, the detent 5606 of the distal attachmentportion 5604 can be releasably locked relative to the proximalattachment portion 5622 when the detent 5606 is held in the lock slot5638. Furthermore, in certain embodiments, the latch 5630 can holdand/or support the spring 5636 b against the detent 5606 until the latchis again moved to the unlatched position. In various embodiments, torelease the DLU 5602 from the shaft 5620, a user can again move thelatch 5630 from the latched position to the unlatched position, suchthat the detent 5606 can be rotated out of the lock slot 5638. In suchembodiments, the rotation of the detent 5606 again compresses and/ordeforms the spring 5636 b until the distal attachment portion 5604 iswithdrawn from the proximal attachment portion 5622.

Further to the above, the surgical instrument can be configured toidentify, or at least attempt to identify, the end effector that hasbeen assembled to the surgical instrument. In certain embodiments, asdescribed in greater detail further below, the end effector can includeelectrical contacts which can engage corresponding electrical contactson the shaft of the surgical instrument when the end effector isassembled to the shaft. In such embodiments, the controller of thesurgical instrument can establish a wired connection with the endeffector and signal communication between the controller and the endeffector can occur through the electrical contacts. As described ingreater detail below, the end effector can include at least one datumstored thereon which can be accessed by the controller to identify theend effector. The at least one datum can include a bit, more than onebit, a byte, or more than one byte of information, for example. Incertain other embodiments, the end effector can include a transmitterwhich can be in wireless signal communication with the controller of thesurgical instrument. Similar to the above, the end effector can includeat least one datum stored thereon which can be transmitted to thecontroller to identify the end effector. In such embodiments, thecontroller of the surgical instrument can include a receiver, or utilizea receiver, which can receive the transmission from the end effector.Such a receiver can be positioned in the shaft and/or the handle of thesurgical instrument, for example.

As the reader will appreciate, an end effector which communicateswirelessly with the controller, for example, can be configured to emit awireless signal. In various circumstances, the end effector can beconfigured to emit this signal once or more than once. In certaincircumstances, the end effector can be prompted to emit the signal at adesired moment and/or repeatedly emit the signal in a continuous manner.In some circumstances, the end effector can include a switch which canbe operated by the user of the surgical instrument before, during,and/or after the end effector of the surgical instrument is assembled tothe surgical instrument. In various embodiments, the end effector switchcan comprise an on/off, or power, switch which can be closed, oroperated, to activate the end effector. In at least one such embodiment,the end effector can include at least one power source, such as abattery, for example, which can be utilized by the transmitter to emitthe signal when the on/off switch is closed. Upon activation of the endeffector, in various circumstances, the controller of the end effectorcan be configured to generate the signal and emit the signal via thetransmitter. In some circumstances, the end effector may not emit thesignal until the end effector is activated. Such an arrangement canconserve the power of the battery, for example. In certain embodiments,the surgical instrument can be placed in an operating mode where it canawait the signal from the end effector before the end effector switch isactuated. In various circumstances, the surgical instrument can be in astandby, or low-power, operating mode wherein, once the signal has beenreceived by the controller, the controller can place the surgicalinstrument in a fully-powered operating mode. In some embodiments, theend effector switch can instruct an end effector controller to emit thesignal to the surgical instrument controller. Such a switch may or maynot comprise a power switch; however, such a switch could be selectivelyactuated by the user to prompt the end effector to emit the signal at adesired moment and/or continuously from a desired moment forward.

Turning now to FIG. 114, an end effector, such as end effector 9560, forexample, can include one or more electrical contacts, such as contacts9561, for example, which can be utilized to activate the end effector9560. For instance, turning now to FIG. 112, the shaft 9040 of thesurgical instrument can include a contact bridge 9562 which can beconfigured to short, or electrically connect, two or more of thecontacts 9561 when the end effector 9560 is assembled to the shaft 9040.The bridge 9562 can complete a circuit including two contacts 9561, abattery 9564, and at least one integrated circuit 9566 defined on aprinted circuit board 9565. Once the circuit is completed, further tothe above, the battery 9564 can power the integrated circuit, orcircuits, 9566 and the end effector 9560 can be activated. In variouscircumstances, the integrated circuit, or circuits, 9566 and an antenna9567 defined on the printed circuit board 9565 can comprise thecontroller and transmitter discussed above. In certain embodiments, theshaft 9040 can include a biasing member, such as a spring 9563, forexample, which can be configured to bias the bridge 9562 into contactwith the electrical contacts 9561. Prior to the bridge 9562 connectingthe electrical contacts 9561 and/or after the end effector 9560 has beendetached from the shaft 9040, the circuit can be open, power from thebattery 9564 may not be supplied to the integrated circuit 9566, and/orthe power supplied to the integrated circuit 9566 may be reduced, andthe end effector 9560 can be in an inactivated condition. As a result ofthe above, in such embodiments, the assembly of the end effector can beactivated as a result of assembling the end effector to the surgicalinstrument. In various instances, further to the above, the end effectorand the surgical instrument can be constructed and arranged such thatonly the complete and proper assembly of the end effector to thesurgical instrument will activate the end effector.

As discussed above, referring now to FIG. 111, an end effector can beattached to the surgical instrument, indicated by step 9600, activated,indicated by step 9602, and then evaluated by the surgical instrument,indicated by step 9604. When the surgical instrument is attemptingevaluate a wireless signal from an activated end effector, further tothe above, the surgical instrument can be configured to assess whetherthe signal is complete. In various embodiments, asynchronous serialcommunication between the end effector and the surgical instrument canbe utilized to assess whether the signal received by the surgicalinstrument is complete. For instance, the end effector can emit a signalcomprising a start bit which precedes a frame of data, such as a byte ofinformation, for example, and/or a stop bit which follows the frame ofdata. In such instances, the start bit, the byte of data, and the stopbit can comprise a 10-bit character frame, or bit pattern, for example.When the controller of the surgical instrument can identify the startbit and the stop bit of a bit pattern, in such instances, the controllercan assume that the byte of data, or the bits of data, received betweenthe start bit and the stop bit is correct and/or otherwise complete. Invarious circumstances, the start bit and/or the stop bit can comprise astop period before the next byte of information is transmitted and/orbefore the previous byte of information is communicated once again.

Further to the above, turning now to FIG. 110, the controller of thesurgical instrument can compare the bit pattern, or certain bits of thedata, to determine whether the data that it has received is correctand/or otherwise complete. In various circumstances, the data can betransmitted in such a way that the controller can evaluate the data andcompare the data to a bit pattern template, or templates, in which itwas expecting to receive the data. For instance, such a template can beconfigured and arranged such that the most significant bit of data, suchas the left-most bit of data, for example, comprises a 1, for example.In the event that the controller is able to identify that the mostsignificant bit of data equals a 1, referring to step 9700 in FIG. 110,the controller can perform a XOR operation on the data and compare thedata to the bit pattern template, or templates, available to thecontroller, as indicated in step 9702. An XOR operation is known and adetailed discussion of the same is not provided herein for the sake ofbrevity. In the event that the bit pattern received by the surgicalinstrument matches a bit pattern template available to the controller,the controller will have identified the end effector. Upon identifyingthe end effector, the controller can access stored information regardingthe end effector in a memory chip accessible by the controller, forexample. In the event that the controller determines that the mostsignificant bit of data in the received bit pattern does not equal a 1,referring again to step 9700, the controller can perform a bit shiftoperation. Many bit shift operations are known, such as arithmeticshifts, logic shifts, and/or circular shifts, for example, which can beutilized to eliminate bad data bits which were received prior to thedesired bit pattern. In various circumstances, the leading, orleft-most, 0 data bits can be eliminated, referring now to step 9704 inFIG. 110, and the bit pattern can be shifted to the left, for example,until the leading bit is a 1. At such point, further to the above, theshifted bit pattern can be compared to the bit pattern templates inorder to identify the end effector. In the event that shifted bitpattern does not match a bit pattern template, the controller can shiftthe bit pattern once again until the next 1 in the bit pattern becomesthe leading bit and the new shifted bit pattern can be compared to thebit pattern templates. Such a shifting and comparing operation can beperformed any suitable number of times until the end effector isidentified and/or the surgical instrument deems that the end effector isunidentified.

As the reader will appreciate, a surgical instrument can includeinformation regarding any suitable number of end effectors. When an endeffector has been identified by the surgical instrument, further to theabove, the surgical instrument can access stored information relating tothe end effector. For instance, such stored information can instruct thesurgical instrument as to, one, the distance in which a firing member inthe end effector must be advanced to complete a firing stroke and/or,two, the maximum amount of power or torque that the motor of thesurgical instrument should apply to the firing member, for example. Suchinformation, or a set of information, may be unique to each end effectorand, accordingly, identifying the end effector in some way is whatallows the surgical instrument to operate in a desired manner. Withoutsuch information, the surgical instrument may not be able to discern thestroke length required to fully utilize the end effector and/orappropriately limit the power that it applies to the firing member. Invarious circumstances, the surgical instrument may rely on sensorsconfigured to detect when the firing stroke has been completed and/orwhether the power being applied to the firing member is excessive. Suchsensors may prevent the motor of the surgical instrument fromoverpowering and damaging the firing member, for example, of the endeffector.

Further to the above, certain end effectors may be more robust thanother end effectors and, as a result, certain end effectors may be ableto withstand larger forces from the motor of the surgical instrument.Correspondingly, other end effectors may be less robust and, as aresult, may be only able to withstand smaller forces from the motor. Inorder for the surgical instrument to determine the appropriate forces toapply to any specific end effector, further to the above, the surgicalinstrument must identify the end effector attached to the surgicalinstrument. In the event that the end effector cannot identify the endeffector, the surgical instrument can utilize a default operatingprogram, or mode. In the default operating mode, the controller of thesurgical instrument may limit the power that the motor can apply to thefiring member of the end effector, for example, to a minimum, ordefault, power. The minimum power can be selected such that the motorwill not damage an end effector regardless of the end effector that isbeing used. In some circumstances, the parameters for utilizing theweakest, or least robust, end effector that can be used with thesurgical instrument can be utilized by the default operating mode suchthat the surgical instrument will not overpower the end effectorregardless of the end effector being used. In various instances, it isthe advent of motor-powered surgical instruments that may cause an endeffector to be overpowered. Stated another way, end effectors that werepreviously used by hand-driven surgical instruments, and essentiallyunbreakable by such hand-driven surgical instruments, may be easilybreakable by a motor-powered surgical instrument. Moreover, suchprevious end effectors may not include the technology to be identifiedby the motor-driven surgical instruments and, as a result of the defaultoperating program described herein, such previous end effectors maystill be used even with the motor-driven surgical instruments. Thatsaid, the default operating program can also utilize other defaultparameters. For instance, the default operating program can utilize aminimum, or default, firing stroke length. In various instances, thedefault operating program can utilize the shortest stroke length of theend effector that can be used with the surgical instrument. In suchinstances, the firing member will not collide, or crash, with the distalend of the end effector regardless of the end effector being used.

As the reader will appreciate, a surgical instrument which includesstored information regarding the end effectors that can be used with thesurgical instrument, the information available to the surgicalinstrument may need to be updated. For instance, if the preferredoperating parameters with regard to a certain end effector change overtime, the information stored within each surgical instrument may need tobe updated. Furthermore, for instance, the surgical instruments may needto be updated when a new end effector is developed for use with thesurgical instruments. To the extent that the surgical instrument is notupdated in a timely manner, the surgical instrument may not be able toidentify the end effector and, as a result, may use the defaultoperating program described herein. In various embodiments, a surgicalinstrument may not include stored information regarding the endeffectors, or at least certain end effectors, that can be used with thesurgical instrument. In such embodiments, an end effector can includestored information, or parameters, related to the end effector. Suchparameters can be accessed by and/or communicated to the surgicalinstrument. In various circumstances, further to the above, the assemblyof an end effector to the surgical instrument can cause the end effectorto emit a signal which can be received by the surgical instrument. Alsosimilar to the above, the end effector can be prompted to emit thesignal. This signal, in various circumstances, can be transmitted to thesurgical instrument via a wired and/or a wireless connection. In certainembodiments, the surgical instrument can prompt the end effector totransmit the signal.

Further to the above, an end effector can include one or more parametersregarding the end effector stored therein. Such parameters can be storedon one or more memory devices, for example. In various instances, suchparameters can include the desired firing speed of the firing member,the desired retraction speed of the firing member, the distance orstroke in which the firing member is to travel, the maximum torque to beapplied to the firing member by the motor of the surgical instrument,and/or the maximum angle in which the end effector is to be articulatedif the end effector is, in fact, an articulating end effector, forexample. Certain articulating end effectors are disclosed in U.S. patentapplication Ser. No. 13/803,097, entitled ARTICULATABLE SURGICALINSTRUMENT COMPRISING A FIRING DRIVE, the entire disclosure of which isincorporated by reference herein. With regard to the parameter relatedto the maximum articulation angle, the controller can utilize thisparameter to limit the degree in which the articulatable portion of theend effector is articulated. In some instances, the maximum articulationangle can be 45 degrees, for example, as measured from the longitudinalaxis of the surgical instrument shaft. With regard to the parameterrelated to the firing speed and/or the retraction speed of the firingmember, for example, the parameter can communicate a desired speed forthe firing member and/or a percentage or fraction of the maximum speedof the motor, for example. For instance, a value of 3 for the firingspeed could communicate that the controller should operate the motor at30% of its maximum speed, for example, when advancing the firing member.Also, for instance, a value of 5 for the retraction speed couldcommunicate that the controller should operate the motor at 50% of itsmaximum speed, for example, when retracting the firing member. Withregard to the parameter related to the maximum torque of the motor, forexample, the parameter can communicate a maximum value of the torqueand/or a percentage or fraction of the maximum torque of the motor, forexample. Furthermore, with regard to the parameter related to the strokelength of the firing member, for example, the parameter can communicatethe desired distance in which the firing member is to be advanced and/orretracted and/or a percentage or fraction of the maximum stroke lengthof the surgical instrument. For instance, a value of 60 could indicatethat the firing stroke should be 60 mm, for example. In variousinstances, the values of the parameters can be communicated in anysuitable format, including a binary format comprising bits and/or bytesof data, for example. An exemplary embodiment of a parameter array isdepicted in FIG. 110A.

In various embodiments, further to the above, the surgical instrumentcan be configured to obtain the parameters from the end effector in aspecific order. For instance, a signal emitted from the end effector cancomprise a start bit, a first bit pattern for a first parameter, such asthe maximum articulation angle, a second bit pattern for a secondparameter, such as the firing speed, a third bit pattern for a thirdparameter, such as the retraction speed, a fourth bit pattern for afourth parameter, such as the maximum motor torque, a fifth bit patternfor a fifth parameter, such as the stroke length, and a stop bit, forexample. This is but one example. Any suitable number of parameters maybe communicated as part of the signal. Furthermore, any suitable numberof start bits and/or stop bits may be utilized. For instance, a startbit may precede each parameter bit pattern and/or a stop bit may followeach parameter bit pattern. As discussed above, the utilization of atleast one start bit and/or at least one stop bit can facilitate thecontroller of the surgical instrument in analyzing whether the signalfrom the end effector is complete. In certain embodiments, a start bitand/or a stop bit may not be utilized. Moreover, a plurality of signalscan be emitted from the end effector in order to communicate parametersof the end effector to the surgical instrument.

In various circumstances, further to the above, the controller of thesurgical instrument can utilize a checksum to assess whether the signalit has received from an end effector is complete, and/or whether thesignal it has received is authentic, i.e., from a recognized endeffector. A checksum can comprise a value used to ensure data arestored, transmitted, and/or received without error. It can be created bycalculating the binary values, for example, of data and combining thebinary values together using some algorithm. For instance, the binaryvalues of the data can be added together, although various otheralgorithms could be utilized. In embodiments where parameters regardingcertain end effectors are stored in the surgical instrument, asdiscussed above, a checksum value can also be stored for each such endeffector. In use, the controller of the surgical instrument can accessthe parameter data and the checksum value and, after computating achecksum value from the parameter data, i.e., computating a calculatedchecksum value, the controller can compare the calculated checksum valueto the stored checksum value. In the event that the calculated checksumvalue equals the stored checksum value, the controller can assume thatall of the data retrieved from the memory of the surgical instrument iscorrect. At such point, the controller can then operate the surgicalinstrument in accordance with the data uploaded from the memory. In theevent that the calculated checksum value does not equal the storedchecksum value, the controller can assume that at least one datum of theretrieved data is incorrect. In various instances, the controller canthen operate the surgical instrument under the default operatingprogram, further to the above, lockout the firing trigger of thesurgical instrument, and/or otherwise communicate the event to the userof the surgical instrument, for example. In certain instances, thecontroller can re-attempt to upload the data from the memory of thesurgical instrument and re-perform the checksum computation andcomparison discussed above. In the event that the re-calculated checksumvalue and the stored checksum value match, the controller can thenoperate the surgical instrument in accordance with the data uploadedfrom the memory. In the event that re-calculated checksum value and thestored checksum value are not equal, the controller can then operate thesurgical instrument under the default operating program, further to theabove, lockout the firing trigger of the surgical instrument, and/orotherwise communicate the event to the user of the surgical instrument,for example.

In embodiments where parameters regarding an end effector is stored inthe memory of the end effector, as discussed above, a checksum value canalso be stored in the memory of the end effector, for example. In use,the controller of the surgical instrument can access the parameter dataand the stored checksum value. In various instances, further to theabove, the end effector can emit one or more signals that communicatesthe parameters and the checksum value to the surgical instrument. As aresult of the above, the stored checksum value and the parameters can betransmitted together and, for the purposes of discussion herein, thechecksum value received by the surgical instrument can be referred to asthe received checksum value. Once the parameter data has been received,similar to the above, the controller can computate a checksum value fromthe parameter data, i.e., computate a calculated checksum value, andcompare the calculated checksum value to the received checksum value. Inthe event that the calculated checksum value equals the receivedchecksum value, the controller can assume that all of the parameter dataretrieved from the end effector is correct. At such point, thecontroller can then operate the surgical instrument in accordance withthe data uploaded from the end effector. In the event that thecalculated checksum value does not equal the received checksum value,the controller can assume that at least one datum of the retrieved datais incorrect. In various instances, the controller can then operate thesurgical instrument under the default operating program, further to theabove, lockout the firing trigger of the surgical instrument, and/orotherwise communicate the event to the user of the surgical instrument,for example. Such occurrences may be more frequent when the parameterdata is communicated from the end effector to the surgical instrumentvia one or more wireless transmissions, for example. In any event, incertain instances, the controller can re-attempt to upload the data fromthe end effector and re-perform the checksum computation and comparisondiscussed above. In the event that the re-calculated checksum value andthe received checksum value match, the controller can then operate thesurgical instrument in accordance with the data uploaded from the endeffector. In the event that the re-calculated checksum value and thereceived checksum value are not equal, the controller can then, furtherto the above, operate the surgical instrument under the defaultoperating program, lockout the firing trigger of the surgicalinstrument, and/or otherwise communicate the event to the user of thesurgical instrument, for example. In various instances, as a result ofthe above, the surgical instrument does not need to store anyinformation regarding the end effectors that are used to operate thesurgical instrument when using the end effector. In such instances, thedata regarding the parameters of an end effector, and the checksum valueused to confirm the integrity of the data, can be entirely stored on theend effector. The surgical instrument can include an operating programthat only requires sufficient input from the end effector in order touse the end effector. A specific operating program for each end effectorthat can be used with the surgical instrument may not be required. Asingle operating program can be used with every end effector. As such,the surgical instrument may not need to be updated to include operatingprograms for additional end effectors and/or modified programs forexisting end effectors, for example.

In addition to or in lieu of the wireless communication systems utilizedto identify the end effector attached to the surgical instrumentdiscussed herein, turning now to FIGS. 149-154, a surgical instrument,in accordance with at least one embodiment, can include means forscanning and identifying an end effector. FIG. 153 illustrates a handle11020 including a bar code reader 11022 which can be configured to scana bar code, illustrated in FIGS. 149 and 150, on an end effector 11060,illustrated in FIGS. 151, 152, and 154. Similar to other embodimentsdisclosed herein, the end effector 11060 can include a shaft portion, ananvil 11062, and/or a staple cartridge 11064, for example, wherein oneor more portions of the end effector 11060 can include a bar codethereon. In some embodiments, the end effector 11060 can include aremovable component 11063 positioned intermediate the anvil 11062 andthe staple cartridge 11064 which can be removed prior to or after theend effector 11060 has been assembled to the surgical instrument. InFIG. 151, a bar code 11065 is depicted as being positioned on the shaftportion of the end effector 11060. In FIG. 152, a bar code 11065 isdepicted as being positioned on the removable component 11063. Invarious embodiments, the handle 11020 of the surgical instrument caninclude a bar code reader, such as bar code reader 11024, for example,configured to read a bar code on an end effector. For instance,referring primarily to FIG. 154, the handle 11020 can include aninternal bar code reader portion 11022 configured to read the bar code11065 defined on the shaft of end effector 11060. In at least one suchinstance, the bar code reader portion 11022 can include a trough 11026sized and configured to receive the shaft of the end effector 11060wherein the bar code reader 11024 can be mounted within and/or relativeto an opening 11027 defined in the trough 11026 such that the bar codereader 11024 can read the bar code 11065. As the reader will appreciate,a multitude of bar code readers and bar code protocols are known, andany suitable ones can be utilized. In some instances, a bar code caninclude bi-directional information which allows the bar code to be readin two different directions, for example. In some instances, a bar codecan utilize multiple layers of information. In some instances, the barcode protocol can include preamble information preceding informationwhich will identify the end effector and/or otherwise supply informationto the surgical instrument which will allow the surgical instrument tooperate, or operate using a specific operating program. In someinstances, a bar code reader can emit one or more light beams which cancontact a plurality of peaks and valleys which comprise the bar code. Insome instances, the valleys of the bar code can extend into, and/or bedefined within, the shaft housing of the end effector. The emitted lightbeams can be reflected back to the bar code reader where they can beinterpreted. That said, the bar code reader 11024 of the handle 11020 ispositioned and arranged within the trough 11026 such that the emittedand reflected light beams are confined, or at least substantiallyconfined, within the bar code reader portion 11022. In this way, the barcode reader 11024 may not accidentally or unintentionally scan adifferent end effector, i.e., an end effector other than the one that isgoing to be assembled to the surgical instrument, which may be presentin the surgical suite.

In various instances, further to the above, an end effector can bepassed through the bar code reader of a surgical instrument before theend effector is assembled to the surgical instrument. In variousalternative embodiments, the surgical instrument can include a movablebar code reader which can be utilized to scan the bar code of the endeffector after the end effector has been assembled to the surgicalinstrument. In any event, once the end effector has been identified, inat least some circumstances, the controller can access an operatingprogram configured to use the identified end effector. In a way, the barcode can comprise a boot loader. In other circumstances, as outlinedelsewhere herein, the bar code can supply the controller with thenecessary information, or parameters, to utilize a common operatingsystem. In some circumstances, each end effector can be identified witha serialized number such that any two end effectors, eventhough they maybe the same type of end effector, may have two different bar codesthereon. In such circumstances, the controller can be configured torefuse to use an end effector that has been previously scanned by thesurgical instrument. Such a system could prevent an at least partiallyexpended end effector from being used again, for instance.

As discussed above, an end effector can be configured to communicatewith a surgical instrument through a wired connection and/or a wirelessconnection. With regard to a wired connection, turning now to FIG. 115,the proximal end of an end effector, such as proximal end 9969 of endeffector 9960, for example, can comprise a plurality of electricalcontacts 9968 which can be placed in electrical communication with aplurality of electrical contacts 9948 arranged on and/or within a distalend 9942 of a shaft 9940 of a surgical instrument. Referring primarilyto FIG. 116, each electrical contact 9968 can include a contact element9967 at least partially positioned within an element cavity 9965. Eachelectrical contact 9968 can further include a biasing member, such as aspring 9966, for example, positioned intermediate the contact element9967 and an interior sidewall of the element cavity 9965. The spring9966 can be configured to bias the contact element radially outwardly.The contact element 9967 can comprise a stop 9964 protruding therefromwhich can be movably biased into engagement with another interiorsidewall of the element cavity 9965 by the spring 9966, at least priorto the end effector 9960 being assembled to the shaft 9940. Theinteraction between the stop 9964 and the sidewall of the element cavity9965 can arrest the outward movement of the contact element 9967. Whenthe end effector 9960 is assembled to the shaft 9940, the contactelements 9967 of the electrical contacts 9968 can be pushed inwardly bythe shaft electrical contacts 9948 against the biasing force applied bythe springs 9966, as illustrated in FIG. 116. In various circumstances,each pair of contacts 9948 and 9968 can complete a circuit, orcommunication channel 9950. While three pairs of contacts areillustrated, any suitable number of contacts and/or communicationchannels could be utilized. In various embodiments, referring to FIG.117, shaft contacts 10048 can each comprise a movable element 10047 anda biasing spring 10046 configured to push the movable elements 10047against the corresponding end effector contacts 10068. In certainembodiments, turning now to FIG. 118, one or both of the end effectorcontacts and the shaft contacts can comprise a flexible portion. Forinstance, an end effector can comprise flexible contacts 10168 which canresiliently engage the corresponding shaft contacts 9948.

With regard to the embodiments described above, in variouscircumstances, the end effector can be assembled to the shaft along alongitudinal axis. In such circumstances, referring primarily to FIG.115, the proximal-most end effector contact 9968 will first come intoelectrical contact with the distal-most shaft contact 9948. As thereader will appreciate, the end effector 9960 has not been completelyattached to the shaft 9940 when such contacts come into engagement.While such an engagement between these contacts may be temporary, i.e.,until the end effector 9960 is seated deeper into the shaft 9940, thesurgical instrument controller can become confused and misinterpret oneor more signals from the end effector 9960. Similar confusion may ariseas the longitudinal array of end effector contacts 9968 progressivelycomes into contact with the longitudinal array of shaft contacts 9948until the end effector 9940 is fully seated. In various embodiments, thecontroller of the surgical instrument can be configured to ignore thesignals transmitted through the contacts until the proximal-most endeffector contact 9968 is engaged with the proximal-most shaft contact9948. Turning now to FIGS. 119 and 120, one of the contact pairs may bedifferent than the other contact pairs such that the controller canidentify when that pair of contacts has been mated and, as a result, theend effector has been completely seated. For instance, an end effectorand a shaft of a surgical instrument can include a first pair ofcontacts 10248 a, 10268 a, a second pair of contacts 10248 b, 10268 b,and a third pair of contacts 10248 c, 10268 c wherein the third pair ofcontacts can be different than the first pair of contacts and the secondpair of contacts. When the first pair of contacts 10248 a, 10268 a havebeen mated, a contact element 10267 a can be pushed inwardly such that afirst connection portion 10263 a of the contact element 10267 a comesinto contact with a first path portion 9951 a of a communication path9950 a and a second connection portion 10264 a of the contact element10267 a comes into contact with a second path portion 9952 a of thecommunication path 9950 a. In such a position of the contact element10267 a, the first path portion 9951 a and the second path portion 9952a can both transmit a signal through the contact element 10267 a. Whenthe second pair of contacts 10248 b, 10268 b have been mated, a contactelement 10267 b can be pushed inwardly such that a first connectionportion 10263 b of the contact element 10267 b comes into contact with afirst path portion 9951 b of a communication path 9950 b and a secondconnection portion 10264 b of the contact element 10267 b comes intocontact with a second path portion 9952 b of the communication path 9950b. In such a position of the contact element 10267 b, the first pathportion 9951 b and the second path portion 9952 b can both transmit asignal through the contact element 10267 b. When the third pair ofcontacts 10248 c, 10268 c have been mated, a contact element 10267 c canbe pushed inwardly such that a first connection portion 10263 c of thecontact element 10467 c is out of contact with a first path portion 9951c of a communication path 9950 c and a second connection portion 10264 cof the contact element 10267 c comes out of contact with a second pathportion 9952 c of the communication path 9950 c and into contact withthe first path portion 9951 c. In such a position of the contact element10267 a, the first path portion 9951 c can transmit a signal through thecontact element 10267 c. As a result of the above, the first, second,and third sets can have a specific arrangement of connectivity withtheir respective channel paths when the end effector has been fullyseated and the controller can be configured to evaluate whether thisfully-engaged arrangement is in place. For instance, when the endeffector is initially inserted into the shaft, the third contact 10264 cmay initially come into contact with the first shaft contact 10248 a. Insuch a position, only two path portions, i.e., 9951 a and 9952 a, may beable to communicate a signal from the end effector to the controllerand, as a such, the controller can be configured to detect a differentvoltage drop across the interconnection as compared to the voltage dropthat occurs when five path portions, i.e., 9951 a, 9952 a, 9951 b, 9952b, and 9951 c, are able to communicate the signal when the end effectoris fully seated. Similarly, the end effector can be further insertedinto the shaft until the third contact element 10267 c comes intocontact with the second shaft contact 10248 b and the second contactelement 10267 b comes into contact with the first shaft contact 10248 a.In such a position, only four path portions, i.e., 9951 a, 9952 a, 9951b, and 9952 b may be able to communicate a signal from the end effectorto the controller and, as a such, the controller can be configured todetect a different voltage drop across the interconnection as comparedto the voltage drop that occurs when five path portions, i.e., 9951 a,9952 a, 9951 b, 9952 b, and 9951 c, are able to communicate the signalwhen the end effector is fully seated.

In certain instances, when an end effector is assembled to an elongateshaft of a surgical instrument, the operator can engage the drive systemand/or the articulation system of the end effector to initiate closure,firing, and/or articulating of the end effector, for example. An endeffector can include a first jaw, a second jaw, and one or more sensorsconfigured to detect the position of the first jaw relative to thesecond jaw. Referring now to FIGS. 121-124, an end effector 10360 cancomprise a first jaw, or anvil, 10362 and a second jaw, or staplecartridge, 10364, wherein the anvil 10362 is movable toward and awayfrom the staple cartridge 10364. Oftentimes, the end effector 10360 isinserted through a trocar into a patient where the end effector 10360may not be readily visible even with the assistance of an endoscope. Asa result, the user of the surgical instrument may not be able to readilyassess the position of the anvil 10362 relative to the second jaw 10364.To facilitate the use of the end effector, as mentioned above, the endeffector 10360 can include a sensor for detecting the position of theanvil 10362. In various circumstances, such a sensor can be configuredto detect the gap between the anvil 10362 and the staple cartridge10364. Certain sensors can be configured to detect the rotationalposition of the anvil 10362 relative to the staple cartridge 10364.Sensors are disclosed in U.S. patent application Ser. No. 13/800,025,entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which wasfiled on Mar. 13, 2013, and U.S. patent application Ser. No. 13/800,067,entitled STAPLE CARTRIDGE TISSUE THICKNESS SENSOR SYSTEM, which wasfiled on Mar. 13, 2013. The entire disclosures of U.S. patentapplication Ser. No. 13/800,025, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, which was filed on Mar. 13, 2013, and U.S.patent application Ser. No. 13/800,067, entitled STAPLE CARTRIDGE TISSUETHICKNESS SENSOR SYSTEM, which was filed on Mar. 13, 2013, areincorporated by reference herein. Regardless of the sensor, or sensors,used, the position of the anvil 10362 can be communicated to the user ofthe surgical instrument through a display. Such a display can be locatedon the end effector 10360 and/or a shaft of the surgical instrument,such as shaft 10340, for example. When the display is located on the endeffector, the display may be viewable utilizing an endoscope, forexample. In such instances, the display may be positioned on the endeffector such that it is not obscured by the trocar which allowed theend effector to enter the surgical site. Stated another way, the displaycan be located such that it is distal with respect to the distal end ofthe trocar when in use. When the display is located on the shaft, thedisplay may be positioned on the shaft such that it is not obscured bythe trocar. Stated another way, the display can be located such that itis proximal with respect to the proximal end of the trocar when in use.With reference to the embodiment depicted in FIGS. 121-124, a display10390 is located on the shaft 10340.

With continued reference to FIG. 121, the anvil 10362 of the endeffector 10360 is depicted in a fully-open position. In this position ofthe anvil 10362, a firing member 10330 of the end effector 10360 is in aproximal position and has not yet been advanced distally. As will bediscussed in greater detail below, the firing member 10330 is advanceddistally to move the anvil 10362 toward the staple cartridge 10364. Theposition of the firing member 10330 illustrated in FIG. 121 canrepresent an unfired, proximal-most position of the firing member 10300.When the anvil 10362 is in its fully-open position, referring primarilyto FIG. 125, the anvil display 10390 may not be illuminated. As thereader will appreciate, the anvil display 10390 can depict the positionof the anvil 10362 in one of several different positions. Anvil display10390 happens to be capable of depicting five potential positions of theanvil 10362; however, other embodiments are envisioned which can includean anvil display utilizing more than five indicators or less than fiveindicators. As the anvil 10362 is moved from its open position to itsclosed position, the display 10390 can sequentially depict the positionof the anvil 10362 utilizing indicators 10391-10395. Indicator 10391depicts the anvil 10362 in a slightly-closed position. Indicators 10392,10393, and 10394 depict the anvil 10362 in partially closed positions.Indicator 10395 depicts the anvil 10362 in a fully-closed, or parallel,position. Upon comparing FIG. 121 with FIG. 122, the reader willappreciate that the firing member 10330 has been advanced distally to atleast partially close the anvil 10362. When the anvil 10362 is in theposition depicted in FIG. 122, the anvil position sensor can detect thenew position of the anvil 10362 and the indicator 10391 of the anvildisplay 10390 can be illuminated, as illustrated in FIG. 126. Uponcomparing FIG. 122 with FIG. 123, the firing member 10330 has beenadvanced distally to further close, although not completely close, theanvil 10362. When the anvil 10362 is in the position depicted in FIG.123, the anvil position sensor can detect the new position of the anvil10362 and the indicator 10393 can be illuminated, as illustrated in FIG.127. Upon further comparing FIG. 122 and FIG. 123, the reader willappreciate that the anvil 10362 has been rotated about 10 degrees, forexample, and that, if the anvil 10362 had been rotated only about 5degrees, for example, the indicator 10392 of the anvil display 10390would have been illuminated. Upon comparing FIG. 123 with FIG. 124, thefiring member 10330 has been advanced distally to completely close theanvil 10362. When the anvil 10362 is in the position depicted in FIG.124, the anvil position sensor can detect the new position of the anvil10362 and the indicator 10395 can be illuminated, as illustrated in FIG.128. Upon further comparing FIG. 123 and FIG. 124, the reader willappreciate that the anvil 10362 has been rotated about 10 degrees, forexample, and that, if the anvil 10362 had been rotated only about 5degrees, for example, the indicator 10394 of the anvil display 10390would have been illuminated.

Further to the above, the end effector and/or the surgical instrumentcan include a controller which can be configured to control the anvildisplay 10390. For instance, when the end effector includes the anvildisplay 10390, the controller can be positioned within the end effector.When the shaft of the surgical instrument includes the anvil display10390, and/or any other portion of the surgical instrument includes theanvil display 10390, the surgical instrument can include the controller.In other instances, one of the end effector and the surgical instrumentcan include the anvil display 10390 while the other of the end effectorand the surgical instrument can include the controller. In any event,the anvil position sensor, or sensors, can be in signal communicationwith the controller. The controller can be configured to interpret oneor more signals from the sensor, or sensors, to determine the positionof the anvil 10362. The controller can be in communication with theanvil display 10390 in order to illuminate the indicators 10391-10395 asoutlined above. In various circumstances, each indicator 10391-10395 cancomprise a light emitting diode, for example. In such circumstances,each light emitting diode can be placed in electrical communication withan output channel of a microprocessor of the controller such that thecontroller can selectively illuminate a light emitting diodeindependently of the other light emitting diodes. In various instances,the controller can continuously evaluate the position of the anvil 10362based on data from the anvil sensor and, utilizing this data,continuously update which indicator is illuminated. For instance, whenthe anvil 10362 is being closed or opened, the controller may track theposition of the anvil 10362 and promptly display this information to theuser of the surgical instrument through the indicators 10391-10395. Suchinstances may provide the user with real-time, or nearly real-time,feedback as to the position of the anvil 10362. In other instances, thecontroller may wait to display the position of the anvil 10362 untilafter the anvil 10362 has stopped moving, or at least substantiallystopped moving, for a certain period of time, for example. As the readerwill appreciate, the indicators 10391-10395 can represent discretepositions of the anvil 10362; however, it is likely that the anvil 10362may only momentarily pass through each of these discrete positions whenit is closed, for example. In various circumstances, the controller mayutilize an algorithm in order to decide which indicator to illuminate.For instance, the controller can apply an algorithm which determineswhich indicator more accurately represents the position of the anvil10362 even though the anvil 10362 may not be aligned with any of thediscrete positions that can be represented by the indicator display10390. In various circumstances, the controller can illuminate twoadjacent indicators in the indicator display 10390 when the anvil 10362is positioned intermediate the two discrete positions represented by thetwo adjacent indicators.

In various instances, further to the above, the indicators 10391-10395can each comprise a light emitting diode which emits the same colorlight, or at least substantially the same color light. In otherinstances, one or more of the indicators 10391-10395 can emit a colorwhich is different than the other indicators 10391-10395. For instance,indicator 10391 could be configured to emit a yellow color whileindicators 10392-10395 can be configured to emit a green color, forexample. As the reader will appreciate, referring to FIG. 122, thetissue T positioned between the anvil 10362 and the cartridge 10364 maynot be adequately clamped by the anvil 10362 when the anvil 10362 is inthe partially-closed position illustrated in FIG. 122 and, when theindicator 10391 associated with this position of the anvil 10362 isilluminated yellow, the user of the surgical instrument may be remindedto take caution before moving the end effector 10360 and/or continuingthe firing process. In some instances, one or more of the indicators10361-10365 can each be configured to emit more than one color. Forinstance, each indicator 10361-10365 can comprise a light emitting diodeconfigured to emit a green color and a red color. In such instances, theindicators 10361-10365 can emit a green color when indicating theposition of the anvil 10362 as outlined above or, alternatively, emit ared color when an error exists with the end effector 10360 and/or thesurgical instrument.

As discussed above, an anvil of an end effector can be movable relativeto a staple cartridge between an open position and a closed position andthe surgical instrument system can be configured to detect the movementof the anvil and communicate the movement of the anvil to the user. Thatsaid, embodiments are envisioned in which the staple cartridge ismovable relative to the anvil. In at least one such embodiment, theanvil may be fixed or non-pivotable. When fixed or non-pivotable, theanvil may extend rigidly from a portion of the end effector frame;however, that portion of the end effector frame, the anvil extendingtherefrom, and the staple cartridge may be articulatable relative toanother portion of the end effector or the shaft of the surgicalinstrument. Whether or not the end effector is articulatable, in suchembodiments, the staple cartridge can be pivotable relative to theanvil. The systems and methods described herein for detecting themovement of the anvil can be adapted to detecting the movement of thestaple cartridge. Moreover, the systems and methods described herein fordisplaying the movement of the anvil can be adapted to displaying themovement of the staple cartridge.

In various instances, an operator may desire to retract the drive memberduring a firing stroke. The surgical instrument disclosed in Zemlok '763employs a retraction assembly that comprises a manually-drivenmechanical interface with the drive tube that is activated by ratchetinga retraction lever mounted on the handle. Such arrangement purports toenable the clinician to retract the firing rod and ultimately theloading unit drive member should the power source become interrupted orthe motor or control system fail during firing. However, such retractionassembly can be difficult to effectively operate due to the fact thatthe motor and the motor gear box remained engaged during the ratcheting(activation) process. Thus, the retraction assembly of that device mustbe able to develop enough torque to rotate the gears in the gear box andmotor shaft to enable the drive tube to be manually rotated. Thegeneration of such forces may place extreme stress on the retractionassembly components which may lead to catastrophic failure of theretraction assembly. The surgical instruments 10 depicted in FIGS. 1-28may be configured with unique and novel retraction assembly arrangementswhich may avoid this problem and others.

For example, the surgical instrument 10 may include a retractionassembly 120 that includes a retraction chassis 124 that has a topportion 126 and a bottom portion 128. In various forms, the retractionassembly 120 interfaces mechanically with the drive tube 102 via a drivegear 130 and a retraction gear 132. See FIG. 5. The drive gear 130 isnon-rotatably attached to the drive tube 102 such that rotation of thedrive gear 130 imparts rotation on the drive tube 102. The drive gear130 and the retraction gear 132 may comprise bevel gears or the like topermit intermeshing engagement therebetween as shown in FIG. 5. Theretraction gear 132 may be coupled to a first spindle 134 (FIGS. 4 and5) which is substantially perpendicular to the top and bottom portions126 and 128 of the retraction chassis 124 and extends therebetween. Thespindle 134 may be supported for rotational travel about a spindle axis“SA-SA” that is substantially perpendicular to the longitudinal axis“LA-LA” of the surgical instrument 10. See FIG. 5. In various forms, theretraction gear 132 may have a first spur gear 136 attached thereto. Thefirst spur gear 136 interfaces with a second spur gear 138 that isoperably supported on a second spindle 137 which is also disposed in asubstantially perpendicular manner between the top and bottom portions126 and 128 of the retraction chassis 124 and is rotatable around asecond shaft axis “SA′-SA′” defined thereby. The second spur gear 138 issupported for meshing engagement with a third spur gear 140 which isdisposed on the first spindle 134. The third spur gear 140 is attachedto a first clutch portion 144 of a unidirectional clutch assembly 142.The clutch assembly 142 further includes a second clutch portion 146that is rotatably disposed on the first spindle 134 above the firstclutch portion 144. A spring or springs (not shown) may be disposedbetween the first and second clutch portions 144 and 146 therebymaintaining the first and second clutch portions 144 and 146 in a raised“non-interlocking” orientation as illustrated in FIG. 5.

It will be appreciated that as the drive tube 102 is rotated, the drivegear 130 will impart rotation to the first, second and third spur gears136, 138, 140 as well as to the first clutch portion 144 and therespective spindles 134, 137. Because the second clutch portion 146 canrotate about the spindle 134 and is biased out of engagement with thefirst clutch portion 144 by the spring arrangement disposed therebetween(not shown), the rotation of the first clutch portion 144 is nottranslated to the second clutch portion 146. As can be seen in FIG. 5,the first and second clutch portions 144 and 146 include a plurality ofinterlocking teeth 148 that each have a flat interlocking surface and asloping slip surface. As will be discussed in further detail below, thesecond clutch portion 146 may be biased into meshing engagement with thefirst clutch portion 144 by the retraction lever 150. The slip surfaceson the teeth 148 allow for the interlocking surfaces to come in contactwith each such that rotation of the second clutch portion 146 causes thefirst clutch portion 144 to rotate. Rotation of the first clutch portion144 also causes all of the interfacing gears to rotate as well toultimately impart rotational motion to the drive tube 102 about thelongitudinal tool axis LA-LA.

Referring now to FIG. 6, the retraction lever 150 may include anelongated handle portion 152 that includes a camming portion 154. Thecamming portion 154 may include an opening which may house aunidirectional needle clutch (not shown) which is supported inmechanical cooperation with a fitting (not shown) that may be attachedto the first spindle 134 to enable the retraction lever 150 to rotateabout the first spindle 134. Zemlok '763 further describes an operationof such a unidirectional needle clutch and fitting arrangement and wasincorporated by reference herein in its entirety. In various forms, theretraction lever 150 includes a one or more camming members 156 thateach have a camming surface 158 thereon. In a first orientation, theretraction lever 150 is disposed along a lever pocket 14 of the housing12 as shown in FIG. 1. The spring disposed between the first and secondclutch portions 144, 146 serves to bias the retraction lever 150 againstthe top portion 126 of the retraction chassis 124. As can be seen inFIG. 6, the camming members 156 are disposed within corresponding camslots or pockets 160 in the top portion 126 of the retraction chassis124. The retraction lever 150 is maintained in a first orientation by areturn spring 162 that is mounted between the top portion 126 of theretraction chassis 124 and the camming portion 154 of the retractionlever 150. The camming members 156 and the cam slots 160 prevent furtherrotation of the retraction lever 150.

In use, when the retraction lever 150 is moved out of the lever pocket14 (FIG. 1) in the housing 12, the camming members 156 interface withthe corresponding cam slots 160 to bias the camming portion 154 of theretraction lever 150 in a downward direction against the biasing forceof the spring(s) positioned between the first and second clutch portions144, 146. Such downward movement compresses the spring(s) and pushes thefirst and second clutch portions 144, 146 into interlocking engagement.Rotation of the camming portion 154 in a counterclockwise directionactuates the needle clutch which interfaces with the fitting and thefirst spindle 134. Continual actuation of the retraction lever 150rotates the clutch assembly 142 which in turn rotates the spur gears136, 138, 140 and the retraction and drive gears 132 and 130. This inturn rotates drive tube 102 about the longitudinal tool axis “LA-LA”.Because the firing rod 104 is in threaded engagement with the drive tube102, rotation of the drive tube 102 in the above-described mannerresults in the retraction (or proximal axial travel) of the firing rod104 into the drive tube 102.

In operation, the drive tube 102 may be configured to be rotated in adirection that is opposite to the retraction direction (e.g., in aclockwise direction, for example) about the longitudinal tool axis”LA-LA” by the motor 100. Such rotation of the drive tube 102 causes thefiring rod 104 to move axially in the distal direction “DD”. Thisadvancement of the firing rod 104 and the drive member 60 of the loadingunit 20 may be referred to herein as a “firing” action. As can be seenin FIG. 5, for example, a gear assembly 170 is employed to establish anamount of driving torque required to drive the firing rod 104 in thedistal direction “DD” to actuate the loading unit 20. The gear assembly170 may include a gear box housing 172 that is coupled to the motor 100.For example, the gear box housing 172 may be coupled to the motorhousing 101 by screws 103 or other mechanical fasteners and/or fastenerarrangements. The gear assembly 170 and motor 100 may be collectivelyreferred to as “drive unit”, generally designated as 186.

The gear box housing 172 may be rotatably supported in a motor retainerportion 190 that is integrally formed or otherwise non-rotatablysupported by the housing 12. Such arrangement permits the drive unit 186to rotate within the housing 12 about the longitudinal tool axis“LA-LA”, but prevents axial movement thereof within the housing 12. Themotor 100 may, for example, be powered by the power source 200 of thetype described in further detail in Zemlok '763 and/or the power system2000 (FIG. 129).

To facilitate supply of electrical current to the drive unit 180 and,more particularly, to the motor 100, a unique contact arrangement 210may be employed. For example, the contact arrangement 210 may include anannular negative motor contact 212 and an annular positive motor contact114 supported on the motor housing 101 as can be seen in FIG. 4. A fixednegative contact 216 may be supported within the housing 12 for slidingcontact with the negative motor contact 112. Similarly a fixed positivecontact 218 may be supported for sliding contact with the positive motorcontact 214 as the drive unit 180 rotates within the housing 12. Thefixed negative and positive contacts 216, 218 may comprise flexiblespring-like contacts to facilitate assembly and adjustment of the driveunit 186 within the housing 12. The fixed negative contact 216 may beelectrically coupled to the power source 200 by a negative lead 220 andthe fixed positive contact 218 may be electrically coupled to the powersource 200 by a positive lead 222. Such contact arrangement enableselectrical power to be supplied from the power source 200 to the motor100 while facilitating rotation of the drive unit 186 within the handlehousing about the longitudinal tool axis “LA-LA”.

Referring to FIG. 5, the gear assembly 170 may comprise a planetary geararrangement that is operably coupled to the motor shaft 107. In onearrangement for example, a ring gear 173 may be formed on the innersurface of the gear box housing 172. A primary sun gear 171 may becoupled to the motor shaft 107. The primary sun gear 171 may besupported in meshing engagement with a plurality of first planetarygears 175 that are supported on a first planetary gear carrier 174 suchthat they are also in meshing engagement with the ring gear 173. A firstsun gear 176 may be formed on or otherwise attached to the firstplanetary gear carrier 174 and may be supported in meshing engagementwith a plurality of second planetary gears 178 that are supported on asecond planetary gear carrier 177. The second planetary gears 178 mayalso be supported in meshing engagement with the ring gear 173. A secondsun gear 179 may be formed on or otherwise attached to the secondplanetary gear carrier 177 and may be supported in meshing engagementwith a plurality of third planetary gears 181. The third planetary gears181 may be supported on a third planetary gear carrier 180 in meshingengagement with the ring gear 173. A third sun gear 183 may be formed onor is otherwise attached to the third planetary gear carrier 180 and isin meshing engagement with a plurality of fourth planetary gears 187that may be attached to an output shaft unit 184 that is rotatablysupported within the gear box housing 172 by a bearing 185. The fourthplanetary gears 187 may also be supported in meshing engagement with thering gear 173.

FIG. 7 illustrates one arrangement for rotatably supporting the driveunit 186 within the housing 12. As can be seen in that Figure, a motormount boss 192 of the motor retainer 190 may include a gear box housingsegment 196 that is rotatably supported therein. In one arrangement, forexample, the gear assembly 170 is rotatably supported in the gear boxhousing segment 196 by bearing 185. Similarly, the motor 100 isrotatably supported within a motor mount housing portion 13 by a bearing198. Other methods of rotatably supporting the drive unit 186 within thehousing 12 may also be employed.

The output shaft unit 184 may be operably coupled to a clutch 230 (FIG.5) of the type and construction disclosed in Zemlok '763 which has beenherein incorporated by reference in its entirety. Further detailsregarding the construction and operation of such clutch 230 may beobtained from that publication. In an alternative embodiment, however,the clutch 230 may be replaced with a shaft-to-shaft coupler or sleevearrangement that serves to facilitate the coupling of the output shaftunit 184 directly to the drive tube 102.

When the axially movable drive beam of the surgical instrument disclosedin Zemlok '763 became jammed or power was lost to the instrument, theuser had to employ the retraction assembly to retract the drive beamback to a starting position to facilitate removal of the loading unit.However, effective retraction was difficult because the retractionsystem had to generate a sufficient amount of torque necessary toreverse the plurality of gear arrangements in the gear assembly. Thus,such retraction system could be extremely difficult to operateeffectively.

At least one surgical instrument embodiment disclosed herein employs aunique and novel releasable drive unit locking system, generallydesignated as 240, to address such problem. As will be discussed infurther detail below, for example, when the releasable drive unitlocking system 240 is in a “locked” position, the drive unit 186 isprevented from rotating within the handle housing 12. The drive unit 186is retained in the locked position when the surgical instrument is“fired” to facilitate transfer of the motor torque from the motor 100through the gear assembly 170 and ultimately to the drive tube 102. Whenit is desirable to activate the retraction assembly 120, the drive unitlocking system 240 is moved to an “unlocked” position to enable thedrive unit 186 to freely rotate within the housing 12 to thereby avoidthe need to generate sufficient retraction torque to reverse the geararrangements in the gear assembly 170. The gear assembly 170 can remainoperably coupled between the motor 100 and the drive tube 102 duringoperation of the retraction assembly 120. In such embodiments, thoughthe gear assembly 170 remains operably coupled to the motor 100 and thedrive tube 102, free rotation of the drive unit 186 can reduce thetorque required to drive the gear assembly 170 as the gear arrangementsreverse to retract the drive tube 102. Such a reduction in requiredtorque can improve the effectiveness of the retraction system.

As can be seen in FIG. 8 for example, the third spur gear 140 of theretraction assembly 120 may include an unlocking cam 141 that isconfigured to actuate a locking pawl assembly 250 of the drive unitlocking system 240. One form of locking pawl assembly 250 is illustratedin FIGS. 9-11. As can be seen in FIG. 10 for example, the locking pawlassembly 250 may include a pawl member 252 that has a locking notch 254formed therein. The locking notch 254 is sized to permit a series ofspaced, first lock wedges 256 formed around the outer circumference ofthe gear box housing 172 to freely pass therethrough. See, e.g., FIGS.12 and 13. A pawl lock wedge 258 is formed on the locking pawl 252 forlocking engagement with any of the first lock wedges 256 as will bediscussed in further detail below. As can also be seen in FIGS. 8-11,the locking pawl assembly 250 may further include a pawl guide rod 260that is configured to be slidably received within a passage 194 in themotor mount boss 192. A pawl spring 262 is journaled on the pawl guiderod 260 and is positioned between the pawl member 252 and the motormount boss 192 to bias a cam engagement portion 264 of the pawl member252 into engagement with the third spur gear 140.

One method of operating the retraction assembly 120 and the drive unitlocking system 240 will now be described with reference to FIGS. 8, 13and 14. FIG. 13 illustrates the drive unit locking system 240 in thelocked position. As can be seen in that Figure, the pawl member 252 isbiased into the distal locking position by the pawl spring 262. When inthat locked position, the pawl lock wedge 258 on the pawl member 252 isin locking engagement with a corresponding one of the first lockingwedges 256 on the gear box housing 172. When in that position, theretraction assembly 120 has not been activated and the gear assembly 170is prevented from rotating within the housing 12. Operation of the motor100 by depressing the main power switch 80 (FIG. 1) results in therotation of the drive tube 102 and ultimately the axial advancement ofthe firing rod 104 which drives the drive beam 60 distally through theloading unit 20.

If, for example, the drive beam 60 becomes jammed in the tissue clampedin the loading unit 20 or power is lost to the motor 100 or for someother reason the motor 100 is unable to reverse the rotation of thedrive tube 102 to ultimately retract the firing rod 104, the clinicianmay employ the retraction assembly 120 to manually retract the firingrod 104 and drive beam 60. FIG. 8 illustrates the retraction assembly120 in the unactuated position (e.g., when the drive unit locking system240 is in the locked position). To commence the manual retractionprocess, the clinician pulls the retraction lever 150 out of the leverpocket 14 in the handle housing 12 (in the “R” direction—see FIG. 6).Movement of the retraction lever 150 in the “R” direction results in therotation of the camming portion 154 of the retraction lever 150 withinthe retraction chassis 124. Such initial rotation of the retractionlever 150 in the “R” direction causes the unlocking cam 141 to engagethe cam engagement portion 264 of the pawl member 252 to bias the pawlmember 252 to the unlocked position thereby enabling the drive unit 186to freely rotate within the handle housing 12. The cam slots 160 in theretraction chassis are located and have a sufficient length tofacilitate this rotational travel of the camming portion 154 of theretraction lever 150 without initially disengaging the clutch assembly142. Thus, the cam slots 160 may be longer than the cam slots located inprior retraction chassis arrangements to facilitate the unlocking of thedrive unit assembly 186 prior to applying the actuation motions whichresult in the rotation of the drive tube 102. For example, in at leastone arrangement, the cam slots 160 may be elongated to facilitaterotation of the retraction lever 150 approximately fifteen degrees. Asthe clinician continues to rotate the retraction lever 150 in the “R”direction, the cam engagement portion 264 will ride along the outercircumference of the unlocking cam 141 on the third spur gear 140.Continued rotation of the retraction lever 150 in the “R” directionresults in the engagement of the camming members 156 on the cammingportion 154 with the ends of their respective cam slots 160 to bias thecamming portion 154 in the downward direction. This downward movementcompresses the spring(s) positioned between the first and second clutchportions 144 and 146 to bring the teeth 148 thereon into meshingengagement with each other. Continued rotation of the camming portion154 in a counterclockwise direction may actuate the needle clutch whichinterfaces with the fitting and the first spindle. Continual actuationof the retraction lever 150 rotates the clutch assembly 142 which inturn rotates the spur gears 136, 138, 140 and the retraction and drivegears 132 and 130. This in turn rotates drive tube 102 and retracts thefiring rod 104.

The retraction lever 150 can be actuated for a predetermined amount oftravel until a portion of the retraction lever 150 abuts a portion ofthe housing 12. Thereafter, the retraction lever 150 is returned to itsfirst position by the return spring 162. This action raises the cammingportion 152 allowing the second clutch portion 146 to also move upwardand disengage the first clutch portion 144. The needle clutch mayrelease the fitting to thereby allow the retraction lever 150 to returnto the first position without affecting the movement of the drive tube102. Once the retraction lever 150 is returned to the first position,the drive unit 186 is once again retained in a locked position. Theratcheting or rotation of the retraction lever 150 may be repeated overand over until the firing rod 104 has been returned to a desiredposition.

Because the gear box housing 172 is free to rotate during theapplication of this rotational motion, the amount of torque required torotate the drive tube 102 and the gears within the gear assembly 170 isgreatly reduced as compared to the torque required to operate priorretraction assemblies. Such arrangement also advantageously serves toprevent the transfer of the torque forces generated by the retractionassembly to the motor shaft 107 while the gear assembly 170 remainsdrivingly coupled to the motor shaft 107. In other words, the gearassembly 170 can remain drivingly coupled between the motor shaft 107and the drive tube 102 during operation of the retraction assembly 120.Such arrangement differs from retraction arrangements disclosed in, forexample, U.S. Pat. No. 7,959,050, which is incorporated by reference inits entirety herein, but which result in the physical decoupling orphysical interruption of portions of the transmission during activationof the retraction system.

FIGS. 15-18 illustrate another surgical instrument 310 that issubstantially similar to surgical instrument 10 described above, exceptfor the differences discussed below. As can be seen in FIG. 16, theinstrument 310 includes a gear assembly 470 that comprises a gear boxhousing 472 that may be coupled to the motor 100 in the manner describedabove, for example. The gear box assembly 470 and motor 100 may becollectively referred to as “drive unit”, generally designated as 486.The gear assembly 470 may be identical to gear assembly 170 describedabove except for the differences discussed below.

In at least one arrangement, the gear box housing 472 may benon-rotatably supported in or integrally formed with a motor retainerportion 190 that is integrally formed or otherwise non-rotatablyattached within the housing 12 in the various manners discussed herein.Because the drive unit 486 does not rotate in this arrangement, it maybe directly wired to the power source. For example, the motor 100 may bepowered in the manner described in Zemlok '763 or other suitablemanners. As can be seen in FIG. 16, the gear assembly 470 may comprise aplanetary gear arrangement that is operably coupled to the motor shaft107. In one arrangement for example, a fixed ring gear 473 may be formedon the inner surface of the gear box housing 472. A primary sun gear 471may be attached to the motor shaft 107. The primary sun gear 471 may besupported in meshing engagement with a plurality of first planetarygears 475 that are supported on a first planetary gear carrier 474. Thefirst planetary gears 475 may also be in meshing engagement with thefixed ring gear 473. A first sun gear 476 may be formed on the firstplanetary gear carrier 474 and be in meshing engagement with a pluralityof second planetary gears 478 that are supported on a second planetarygear carrier 477. The second planetary gears 478 may also be supportedin meshing engagement with the fixed ring gear 473. A second sun gear479 may be formed on or attached to the second planetary gear carrier477 and be supported in meshing engagement with a plurality of thirdplanetary gears 481 supported on a third planetary gear carrier 480. Thethird planetary gears 481 are in meshing engagement with the fixed ringgear 473. A third sun gear 483 may be formed on or otherwise be attachedto the third planetary gear carrier 480. The third sun gear 483 may besupported in meshing engagement with a plurality of fourth planetarygears 487 that are attached to an output shaft unit 484 that isrotatably supported within the gear box housing 472 by a bearing 185.The plurality of fourth planetary gears 487 may be in meshing engagementwith a lockable ring gear 485 that is rotatably mounted in the gear boxhousing 472. The gears 471, 473, 475, 476, 478, 479, 481 and 483 may becollectively referred to herein as gear train assembly 460.

The lockable ring gear 485 may be rotatably mounted within an annularcavity 490 in the motor retainer portion 190 (FIG. 16). Cavity 490 issized to permit the free rotation of the lockable ring gear 485 thereinabout the longitudinal tool axis “LA-LA”. The lockable ring gear 485 maybe installed in the annular passage 490 and then retained in position bya plug member 492 that is pressed into or otherwise retained in theannular passage 490.

The surgical instrument 310 may further include a drive unit lockingsystem 540 that includes a movable shift ring assembly 542. In at leastone form, the shift ring assembly 542 may include, for example, a shiftring 543 that has at least one, and preferably a plurality of, lockingmembers in the form of, for example, pins 544. Pins 544 protrude fromthe shift ring 543 and are configured for selective locking engagementwith the lockable ring gear 485. Each of the locking pins 544 may beslidably received within a corresponding passage 546 in the plug member492. The shift ring 542 is supported for axial movement by a reversinglink 550 that is attached to a clutch clamp 560. As can be seen in FIG.15, the clutch clamp 560 may comprise a spring clamp that is clampedabout a portion of the outer circumference of the third spur gear 140.The clutch clamp 560 may have a lug 562 thereon that is attached to ashifter rod 564. The shifter rod 564 may be somewhat flexible and bepivotally coupled to the shift ring 542. During normal use (i.e., whenthe motor 100 is driving the firing rod 104), the locking pins 544 arein locking engagement with the lockable ring gear 475 to prevent thelockable ring gear 475 from rotating such that the rotational torque istransferred to the output shaft unit 484 and ultimately to the drivetube 102.

When the clinician desires to employ the retraction assembly 120 toretract the firing rod 104, the retraction lever 150 is rotated from thestarting position shown in FIG. 15 in “R” direction. As the retractionlever 150 is rotated, the clutch clamp 560 rotates with the third spurgear 140 to thereby cause the shifter rod 564 to move the shift ring 542in the distal direction “DD”. As the shift ring 542 moves in the distaldirection “DD”, the locking pins 544 move out of locking engagement withthe lockable ring gear 485 to permit the lockable ring gear 485 torotate relative to the gear box housing 472. The clinician continues toratchet the retraction lever 150 to the end position shown in FIG. 18.In at least one arrangement for example, the retraction lever 150 needonly be rotated approximately fifteen degrees to disengage the lockingpins 544 from the lockable ring gear 485. After the clinician releasesthe retraction lever 150, the return spring 162 will return theretraction lever 150 to the starting position and the clinician canrepeat the procedure until the firing rod 104 is retracted to a desiredposition. Because the lockable ring gear 485 is free to rotate withinthe bearing housing 472, rotation of the drive tube 102 and the outputshaft unit 484 will not be resisted by the other gear arrangements inthe gear assembly 470. As such, the amount of ratcheting torque requiredto retract the firing rod 104 is reduced when compared to retractionarrangements that remain operably engaged with the gear arrangements inthe gear assembly during the retraction process. Furthermore, though therequired torque is reduced, the firing rod 104 can remain operablyengaged with the gear assembly 470. In other words, the firing rod 104can remain operably coupled to the motor 100. When the shift ring 542contacts the bearing 185 in the motor mount boss 192, the locking pins544 lockingly engage the lockable ring gear 485. The clutch clamp 560may be configured to slip relative to the third spur gear 140 after theshift ring contacts the bearing 185 or other portion of motor mountingboss 192. Thus, the drive unit locking system 540 serves to facilitaterotation of at least a portion of the drive unit within the handlehousing during the application of retraction motions to the drive tube102 to reduce the amount of retraction torque required to retract thefiring rod 104.

The surgical instrument 610 in FIG. 19 is substantially identical to thesurgical instrument 310 except that the clutch clamp 560 is attached tothe third spur gear 140 in such a way as to eliminate the reversing link550 employed in the surgical instrument 310. As can be seen in FIG. 18for example, the shifter rod 564 is directly connected to the shift ring542. Ratcheting of the retraction lever 150 in the above-mentionedmanner results in the movement of the shift ring 542 and the engagementand disengagement of the locking pins 544 with the lockable ring gear485.

FIGS. 20 and 21 illustrates another surgical instrument 610′ that issubstantially identical to surgical instrument 610 except for thefollowing differences. In this arrangement, for example, at least two“leaf-type” lock springs 620 and ring gear lock members 622 aresupported on the gear box housing 472′ of the gear assembly 470′. As canbe seen in FIG. 20, each lock spring 620 and corresponding lock member622 is supported in a slot 624 in the gear box housing 472′. In thisarrangement, the locking pins 544′ that are attached to the shift ring542 are configured to contact and depress the corresponding lockingspring 620 inwardly to press the corresponding ring gear lock member 622into locking engagement with the lockable ring gear 485. When in thatposition (shown in FIG. 20), the lockable ring gear 485 is preventedfrom rotating in relative to the gear box housing 472′. When the shifterrod 564 pulls the shift ring 542 in the distal direction “DD”, thelocking pins 544′ disengage their corresponding locking spring 620 whichenables the spring 620 to flex to a starting position to enable the ringgear lock members 622 to disengage the lockable ring gear 485 to permitit to rotate relative to the gear box housing 472′. Thus, when theretraction assembly 120 is activated, the lockable ring gear 485 is freeto rotate relative to the gear box housing 472′ to thereby reduce theamount of retraction torque needed to cause the firing rod 104 to beretracted in the proximal direction “PD”.

FIGS. 22-24 illustrate another retraction assembly arrangement forselectively manually retracting a distal portion of the firing rod of asurgical instrument 710 should the distal portion of the firing rod orother component of the surgical instrument to which it is operablyattached become jammed during operation or operational power foradvancing the firing rod assembly is interrupted. Except for thedifferences discussed below, the surgical instrument 710 may be similarin design and operation to the surgical instruments described aboveand/or disclosed in Zemlok '763, which has been incorporated byreference herein in its entirety.

As can be seen in FIGS. 22-24, the surgical instrument 710 includes ahousing 712 that operably supports a firing rod assembly 720. Thehousing 712 may, for example, operably support a motor and gear assembly(not shown) for applying rotary motions to a drive tube which may resultin the axial movement of the firing rod assembly 720 in the variousmanners described herein. In at least one arrangement, the firing rodassembly 720 may include a proximal firing member or rod portion 722that operably interfaces with the drive tube in the various mannersdisclosed herein. In still other surgical instrument arrangements, theproximal firing rod portion 722 may operably interface with other drivearrangements and systems that are configured to apply axial motions tothe proximal firing rod portion 722.

As can be further seen in FIGS. 22-24, the firing rod assembly 720 mayfurther include a distal firing member or rod portion 724 that isoperably coupled to a proximal end of the axially movable drive beam 60of a loading unit 20 coupled thereto in the various manners describedherein. A retraction assembly 730 in the form of a retraction linkageassembly 732 may be pivotally coupled between the proximal firing rodportion 722 and the distal firing rod portion 724. In the illustratedarrangement, the retraction linkage assembly 732 includes an actuatorlink 734 that has a link handle portion 736 that is pinned to theproximal firing rod portion 722. The retraction linkage assembly 732further includes a distal retraction link 738 that is pinned to theactuator link 734 and the distal firing rod portion 724 as shown. In theillustrated embodiment, the housing 712 includes a distally-extendingarticulation housing portion 714 that may also include adistally-extending, shaft housing segment 716. The shaft housing segment716 may serve to axially support the retraction linkage assembly 732 asit axially moves in the distal and proximal directions in response tothe axial movement of the firing rod assembly 720. To facilitate axialmovement of the retraction linkage assembly 732 relative to the shafthousing segment 716, the actuator link 734 extends out through a slot718 formed in the shaft housing segment 716 as shown.

FIG. 22 illustrates the position of the firing rod assembly 720 and theretraction assembly 730 prior to firing. FIG. 23 illustrates theposition of the firing rod assembly 720 and the retraction assembly 730after being fired in the distal direction “DD”. If during the firingprocess, the clinician desires to retract the drive beam 60 back to astarting position, the clinician can simply grasp the link handleportion 736 of the actuator link 734 and pivot it in the “R” directionas shown in FIG. 24 which draws the distal firing rod portion 724 andthe drive beam 60 in the proximal “PD” direction. As illustrated inFIGS. 22 and 23, during firing, the proximal end 725 of the distalfiring rod portion 724 may be normally axially spaced from the distalend 735 of the proximal firing rod portion 734 a distance designated as“RD”. The distance “RD” may remain, for example, unchanged during firingand normal retraction of the firing rod assembly 720 by the drive unit.However, when the clinician activates the retraction assembly, thedistance between the proximal end 725 of the distal firing rod portion724 and the distal end 735 of the proximal firing rod portion 734(distance “RD′”) will be less than distance “RD”. In addition, as can beseen in FIG. 22, the distance between the starting position of thedistal working head 62 of the drive beam 60 and the ending position ofthe distal working head 62 (i.e., after a complete firing stroke) isrepresented as distance “FD”. If desired, the distance “RD” may besufficiently large enough to enable the distal firing rod portion 724 tobe sufficiently retracted (i.e., moved closer to the distal end 735 ofthe proximal firing rod portion 722) to return the working head 62 fromthe ending position back to its starting position. Stated another way,the distal firing rod portion 724 may be retracted a retraction distancethat is at least equal to or greater than the firing distance “FD”. Insuch arrangement, for example, if the working head 65 becomes jammed orotherwise stopped in its ending position, activation of the retractionassembly can fully retract the drive beam 60 to bring the distal workinghead 62 to its starting position wherein the distal working head 62 canpermit the anvil 22 to pivot open and release the tissue.

FIGS. 25-28 illustrate an alternative firing rod assembly 720′ that maybe selectively manually retractable. The firing rod assembly 720′ asshown includes a proximal firing rod portion 722′ that may operablyinterface with the drive tube in the various manners disclosed herein.In still other surgical instrument arrangements, the proximal firing rodportion 722′ may operably interface with other drive arrangements andsystems configured to apply control motions to the proximal firing rodportion 722′. The firing rod assembly 720′ may further include distalfiring rod portion 724′ that is at least partially hollow and operablycoupled to the end of the axially movable drive beam 60 of a loadingunit 20 coupled thereto in the various manners described herein. Forexample, the distal firing rod portion 724′ may have a passage 725therein that is sized to enable the distal firing rod portion 724′ toaxially slide on the proximal firing rod portion 722′ a retractiondistance “RDD”. The retraction distance may be equal to or greater thanthe firing distance “FD” to enable a retraction assembly 730′ to retractthe drive beam 60 a sufficient distance so as to move the working head62 thereof from the ending position “EP” to the starting position “SP”.See FIG. 25. The retraction assembly 730′ may comprise a retractionlatch 732′. The retraction latch 732′ may include a latch handle 735that is movable between a latched position (FIGS. 25 and 26) and anunlatched position (FIGS. 27 and 28). When in the latched position, theretraction latch 732′ affixes the distal firing rod portion 724′ suchthat it is prevented from axial sliding over the proximal firing rodportion 722′ and the distal firing rod portion 724′. When in thatorientation, the proximal firing rod portion 722′ essentially moves as aunit. Thus, when in the latched orientation, the firing rod assembly720′ may be fired in the distal direction “DD” to its ending position“EP” as shown in FIG. 26. Should the drive beam 60 become jammed orpower be interrupted or lost to the instrument during the firing stroke(or for other reasons), the clinician can simply move the retractionlatch handle 735 to the unlatched position (FIG. 27) and then manuallypull the retraction latch 732′ in the proximal direction “PD” as shownin FIG. 28.

The various retraction systems and arrangements disclosed herein mayaddress certain shortcomings commonly encountered by prior retractionarrangements used to retract motor-powered drive members employed bysurgical end effectors. For example, various retraction arrangementsdisclosed herein may facilitate the manual application of retractionmotions to the drive member and/or associated drive arrangements withoutencountering resistance normally provided by the gear/transmissionarrangements associated with the motor, while enabling thegearing/transmission arrangements to remain “drivingly” or physicallycoupled to the motor.

Thus, at least one example comprises a surgical instrument that mayinclude a firing member assembly that may comprise a portion that issupported for selective axial movement in a distal direction and aproximal direction. The instrument may further include a drive unit thatcomprises a motor that includes a motor shaft. A gear assembly may bedrivingly coupled to the motor shaft and include an output shaftassembly that is configured to interface with the firing member assemblysuch that when the motor shaft is rotated in a first rotary direction,the portion of the firing member assembly is axially driven in thedistal direction and when the motor shaft is rotated in a second rotarydirection, the portion of the firing member is axially driven in theproximal direction. The surgical instrument may further comprise aretraction assembly that interfaces with the firing member assembly formanually applying other rotary motions to the firing member assembly inthe second rotary direction when the motor is deactivated. The surgicalinstrument may further comprise locking means that interfaces with theretraction assembly and the drive unit for preventing transfer of theother rotary motions to the motor shaft while the gear assembly remainsdrivingly coupled to the motor shaft.

In accordance with yet another example, the surgical instrument maycomprise a drive unit for generating firing and retraction motions. Theinstrument may further comprise a surgical end effector that isconfigured to perform at least one surgical function in response to anapplication of at least one of the firing and retraction motionsthereto. The surgical instrument may further comprise a firing memberassembly that may include a proximal firing member portion that operablyinterfaces with the drive unit and is configured to operably receiverotary actuation motions therefrom. The firing member assembly mayfurther comprise a distal firing member portion that is supported distalto the proximal firing member portion and is configured to transmit thefiring and retraction motions to the surgical end effector. A retractionassembly may be operably coupled to the proximal firing member portionand the distal firing member portion. The retraction assembly may beselectively movable between an unactuated position wherein theretraction assembly is configured to transfer the firing and retractionmotions from the proximal firing member portion to the distal firingmember portion and an actuated position wherein the distal firing memberportion is axially moved relative to the proximal firing member portion.

Another surgical instrument example may comprise a handle housing thatincludes an elongated shaft assembly that is operably coupled thereto.The elongated shaft assembly may support an axially movable firing rodtherein. A loading unit may be operably coupled to the elongated shaftand be configured to interface with the firing rod. A drive tube may berotatably supported within the handle housing and operably interfacewith the firing rod. The surgical instrument may further comprise amotor that has a motor shaft. The motor may be operably supported withinthe handle housing and be operably coupled to a power source. A gearassembly may be drivingly coupled to the motor shaft and include anoutput shaft assembly that is configured to interface with the drivetube such that when the motor shaft is rotated in the first rotarydirection, the drive tube drives the firing rod in a distal directionand when the motor shaft is rotated in a second rotary direction, thedrive tube drives the firing rod in a proximal direction. A retractionassembly may interface with the drive tube for manually applying otherrotary motions thereto in the second rotary direction when the motor isdeactivated. A locking means may interface with the retraction assemblyand the gear assembly for preventing transfer of the other rotarymotions to the motor shaft while the gear assembly remains drivinglycoupled to the motor shaft.

Referring again to FIGS. 1-3, in various embodiments, the motor 100 ofthe surgical instrument 10 can be operably coupled to a firing element,such as firing element 60, and can drive the firing element 60 throughthe end effector or DLU 20 during a firing stroke. For example, thefiring element 60 can cut tissue and/or fire staples into tissue duringthe firing stroke. A battery can supply current to the motor 100, forexample, and the current supplied to the motor 100 can relate to thetorque generated by the motor 100. Furthermore, the torque generated bythe motor 100 can relate to the firing force exerted by the firingelement 60. The voltage across the motor can relate to the angularvelocity of the motor 100, for example, which can relate to the speed ofthe firing element 60. Referring now to FIG. 63, the motor can define atorque-voltage curve 5802. In various embodiments, the torque-voltagecurve 5802 can have a maximum torque T₁ at optimized voltage V. Atvoltages greater than and/or less than the optimized voltage V, forexample, the torque generated by the motor can be less than the maximumtorque T₁. For example, at a voltage of ½V, the torque-voltage curve5802 can have a torque T₂, which can be less than T₁, for example.

In various embodiments, a control system in signal communication withthe motor can supply current from the battery to the motor. In someembodiments, the control system can include speed management control,which can control the speed of the firing element, for example. Thecontrol system can include a variable resistance circuit and/or avoltage regulation circuit, for example, which can control the currentsupplied to and/or the voltage across the motor. In such embodiments,the control system can control the torque and/or the angular velocity ofthe motor, and thus, the firing force and/or the speed of the firingelement coupled to the motor. For example, a voltage regulation circuitcan regulate the voltage across the motor to affect the speed of thefiring element. Referring to FIG. 63, if the voltage regulation circuitreduces the voltage from the ideal voltage V to ½V, for example, thetorque can be reduced to T₂, which can be less than the maximum torqueT₁, and the speed can be adjusted to speed S₂, for example.

In various embodiments, the control system can include a pulse widthmodulation circuit, and the control system can supply pulses of currentto the motor. Referring primarily to FIGS. 64( a)-65(b), the current canbe pulsed at a constant voltage. In various embodiments, the duty cycleof the pulses, i.e., the duration of the pulses per interval or period,can affect the velocity of a firing element 5804. When the duty cycle ishigher (FIG. 64( a)), each pulse can be a longer portion of theinterval, and, as a result, the motor can drive the firing element 5804at a the faster speed S₁, for example. When the duty cycle is lower(FIG. 64( b)), each pulse can be a shorter portion of the interval, and,as a result, the motor can drive the firing element 5804 at the slowerspeed S₃, for example. In various embodiments, the pulse widthmodulation circuit can provide current pulses to the motor at theoptimized voltage V (FIG. 63) of the motor. In such embodiments, thespeed of the firing element 5804 can be controlled without reducing thetorque generated by the motor. For example, the motor can operate at theoptimized voltage V, to generate the maximum torque T₁, for example, andthe firing element 5804 can be driven through the end effector at areduced speed, such as speed S₃, for example, and/or any suitable speedby altering the width of the voltages pulses.

In various embodiments, the battery can have a volt-ampere limit orpower threshold. In other words, the battery can supply a limited amountof energy per unit time. The power threshold of the battery can berelated to the battery and/or circuit design. For example, thermallimits on the battery and/or the circuit, such as heat capacity and/orwire insulation, for example, can affect the power threshold.Furthermore, the power threshold of the battery can limit the amount ofcurrent supplied to the motor. In various embodiments, a motor utilizingspeed management control, such as pulse width modulation, for example,may not require the maximum volt-amperes of the battery. For example,when the battery supplies current pulses at the maximum or optimizedvoltage to drive the firing element at the desired speed and maximum oroptimized torque, surplus current may not be utilized to drive thefiring element. In such embodiments, the surplus current can be used toproduce additional torque. Referring to FIGS. 66( a)-66(c), a motor caninclude an additional or secondary set of coils, for example, and thesurplus current can be selectively directed to the additional set ofcoils to generate additional torque. In such embodiments, the motor canproduce more torque at lower speeds, for example. In variousembodiments, the control system can maximize the surplus currentsupplied to the secondary set of coils based on the volt-ampere limit ofthe battery, for example. Furthermore, in certain embodiments, thecontrol system can optimize the torque generated by the motor during atleast a portion of the firing stroke.

Referring still to FIGS. 66( a)-66(c), a battery 6002 can selectivelysupply current to a motor 6004. The motor 6004 can include a primary setof coils 6006, and a secondary set of coils 6008, for example. Invarious embodiments, a control system 6020 in signal communication withthe motor 6004 can selectively direct current to the primary set ofcoils 6006 and/or the secondary set of coils 6008. For example, thecontrol system 6020 can supply current to the primary set of coils 6006during a first operating state, and can supply current to the primaryset of coils 6006 and the secondary set of coils 6008 during a secondoperating state, for example. In various embodiments, a switch, such asswitch 6010, for example, can move between an open position and a closedposition to selectively supply current to the secondary set of coils6008, for example. In various embodiments, the sets of coils 6006, 6008can be separately activatable. Furthermore, the control system 6020 caninclude a pulse width modulation circuit 6022, and the battery 6002 cansupply current pulses to at least one of the sets of coils 6006, 6008,for example. In various embodiments, the primary set of coils 6006 canbe coupled to a first circuit 6030 (FIG. 66( a)), and the second set ofcoils can be coupled to a second circuit 6032 (FIG. 66( a)) that isindependent of the first circuit 6030. In other embodiments, the primaryand secondary set of coils 6006, 6008 can be arranged in parallel (FIG.66( b)) or in series (FIG. 66( c)), for example. In certain embodiments,the motor 6004 can include at least one additional set of primary coilsand/or at least one additional set of secondary coils, for example.

In various embodiments, the motor can generate a first amount of torqueduring the first operating state and a second amount of torque duringthe second operating state. The second amount of torque can be greaterthan the first amount of torque, for example. Furthermore, theadditional torque generated by the secondary set of coils 6006 duringthe second operating state may prevent and/or limit lock-out of thefiring element during a firing stroke. For example, referring to FIG.67, the motor can drive the firing element distally during the firstoperating state and can drive the firing element proximally during thesecond operating state. In various embodiments, the motor can generategreater torque when retracting the firing element than when advancingthe firing element. In such embodiments, retraction of the firingelement may be improved. If the firing element becomes jammed, e.g., thetissue is too thick and/or tough for the firing element to cut and/orstaple, the additional torque may be utilized to retract the firingelement, for example. Referring still to FIG. 66, the torque generatedby the motor can be gradually increased during a “soft” start phase 5902of the firing stroke, and/or can be gradually decreased during a “soft”stop 5904, 5906 phase of the firing stroke. For example, when advancingthe firing element, the motor can incrementally, or slowly, increase thefiring speed at the beginning of the firing stroke, and canincrementally, or slowly, decrease the firing speed as the firingelement completes the forward portion of the firing stroke. Furthermore,in various embodiments, the motor can immediately or substantiallyimmediately generate the maximum torque and/or speed when retracting thefiring element. The motor can utilize the additional set of coils 6008(FIGS. 65( a)-(c)) to max-out the torque generated at the beginning ofretraction, for example.

Referring to FIG. 68, the control system can control the firing elementto move at a slower speed during a trial segment 5912 of the firingstroke. For example, when advancing the firing element, the firingelement can initially move at a slower speed to ensure the selectionand/or the placement of the end effector is appropriate for the targetedtissue. Furthermore, as described in greater detail herein, a surgeoncan engage an actuator, such as a switch or a button, for example, toactuate the motor and initiate opening and closing of the end effectorjaws, movement of the firing element, and/or articulation of the loadingunit, for example. Initiation of a trial segment, such as the trialsegment 5912 indicated in FIG. 68, for example, when the actuator isengaged and at the beginning of a motor-driven action can allow thesurgeon to “trial” the surgical action, to ensure that the intendedand/or appropriate surgical action has been initiated. For example, incertain embodiments, a first button can initiate motor-drivenarticulation in a first direction, and a second button can initiatemotor-driven articulation in a second direction. When the surgicalinstrument is rotated and/or oriented “upside down” the placement of thefirst and second buttons can rotate and/or become reversed from thestandard placements as viewed from the operator's perspective. If thefirst direction is the intended articulation direction, it may bedesirable to ensure the loading unit is being articulated in the firstdirection, i.e., that the first button was in fact actuated, during atrial segment. Similarly, if the second direction is the intendedarticulation direction, it may be desirable to ensure the loading unitis being articulated in the second direction, i.e., that the secondbutton was actuated, during a trial segment. In certain embodiments, atrial segment during the initial portion of a surgical action canprovide time for the surgeon to change and/or modify the surgical actionif a non-intended surgical action has been initiated. As described ingreater detail herein, a pulse width modulation circuit, such as pulsewidth modulation circuit 6022, for example, can accomplish the trialsegment during an initial portion of a surgical action.

As discussed above, the motor controller can be configured to utilizepulse width modulation to operate the motor 6004. In various instances,the motor controller can utilize the same pulse width modulation for theprimary set of coils 6006 and the secondary set of coils 6008, forexample. In other instances, the motor controller can utilize a firstpulse width modulation signal for the primary set of coils 6006, and asecond, or different, pulse width modulation signal for the secondaryset of coils 6008. In some instances, the motor controller can utilize apulse width modulation signal for one of the sets of coils 6006, 6008,but not the other. Moreover, the teachings discussed herein can beadapted to motors having more than two sets of coils. For instance, themotor controller can utilize a plurality of pulse width modulationsignals to operate a plurality of coil sets.

In various embodiments, the motor can be a brushed DC motor or abrushless DC motor, for example. In certain embodiments, the motor canbe a stepper motor, such as a hybrid stepper motor, for example. Steppermotors can provide rotation control, such that an encoder is notnecessary. Elimination of the encoder can reduce cost and/or complexityto the motor, for example. Referring to FIGS. 69 and 70, the motor canbe a simplified stepper motor. For example, the motor can comprise fourelectromagnetic poles spaced around the perimeter. Referring now toFIGS. 71-74( c), the motor can be a hybrid stepper motor. The hybridstepper motor can comprise permanent magnets and electromagnets, forexample.

Prior surgical instrument arrangements disclosed in, for example, Zemlok'763 and Zemlok '344 employ two separate motors. One motor is employed,for example, to advance the drive member distally through the loadingunit which results in the closing of the anvil, cutting of tissue andfiring of staples from the staple cartridge supported in the loadingunit. The other motor is employed to articulate the loading unit aboutan articulation joint. Further details relating to motors used forarticulating loading unit arrangements are also disclosed in U.S. Pat.No. 7,431,188, the entire disclosure of which is incorporated byreference herein. The use of two motors in such devices may increase thecomplexity and add to the overall expense of the surgical instrument.For example, such arrangements may double the number of retractionsystems and other mechanisms that could fail during use. The surgicalinstrument 810 depicted in FIGS. 29-31 employs a single motor which maybe selectively employed to fire and articulate a surgical end effectorconfigured to perform at least one surgical procedure in response tofiring motions applied thereto.

In at least one form, for example, the surgical instrument 810 mayemploy many of the same components employed in the various surgicalinstruments described in detail herein. For example, the surgicalinstrument 810 includes a housing 12 that operably supports a motor 100therein that is configured to generate rotary actuation motions. Themotor 100 is operably coupled to a gear assembly 820 that has aselectively positionable drive coupler assembly 840 associated therewithwhich will be described in further detail below. The surgical instrument810 may further include an articulation system, generally designated as859 that operably interfaces with the elongated shaft assembly forapplying articulation motions to the surgical end effector. In one form,for example, the articulation system 859 may include an articulationactuation mechanism, generally designated as 860 which may besubstantially similar to those articulation actuation mechanismsdisclosed in Zemlok '763 and/or Zemlok '344 and/or U.S. Pat. No.7,431,188 except for those differences discussed below. For example, thehousing 12 may include a barrel portion 90 that has a rotatable member92 mounted thereon. The rotatable member 92 may interface with aproximal end of the elongated shaft assembly to facilitate rotation ofthe elongated shaft assembly relative to the housing 12. The rotatablemember 92 may operably support an articulation knob and slip clutcharrangement as disclosed in U.S. Pat. No. 7,431,188. A main articulationgear 94 of that arrangement is represented by broken lines in FIGS. 29and 30. The main articulation gear 94 may be connected to a main shaft95 by a slip clutch as described in the aforementioned U.S. Pat. No.7,431,188 such that rotation of the main articulation gear 94 will causecorresponding rotation of main shaft 95. As further described therein,the articulation knob may serve as an articulation position indicator.The main shaft 95 operably interfaces with a J-channel member 96 thatoperably interfaces with the proximal end of an articulation linkassembly 97. In one form, the articulation link assembly 97 may comprisea proximal articulation link 98 that interfaces with the articulationlink 70 (FIG. 3) in the loading unit 20.

The articulation mechanism 860 may further include an articulation drivetrain arrangement 870 that operably interfaces with the mainarticulation gear 94 and the drive coupler assembly 840. As can be seenin FIGS. 29 and 30, the articulation drive train arrangement 870 mayinclude an articulation drive shaft 872 that is attached to an output ofthe drive coupler assembly 840 as will be discussed in further detailbelow. A first articulation drive gear 873 is attached to thearticulation drive shaft and is in meshing engagement with a centralgear race 875 on a second articulation transfer gear 874 that isrotatably supported within the rotatable member 92. Thus, rotation ofthe first articulation drive gear 873 results in rotation of the secondcentral articulation transfer gear 874. As can be further seen in FIGS.29 and 30, a “third” articulation shaft gear 877 is mounted to a secondarticulation shaft 876 that has a “fourth” articulation worm gear 878thereon. The third articulation shaft gear 877 is in meshing engagementwith the second central articulation transfer gear 875 such thatrotation of the first articulation drive gear 873 ultimately results inthe rotation of the third articulation shaft gear 877 and the secondarticulation shaft 876. The fourth articulation worm gear 878 is inmeshing engagement with the main articulation gear 94 such that rotationof the fourth articulation worm gear 878 results in rotation of the mainarticulation drive gear 94 and ultimately application of articulationmotions to the articulation link assembly 97. As will be discussed infurther detail below, the articulation drive shaft 872 is rotated by themotor 100 when the drive coupler assembly 840 is in an articulationcontrol orientation.

As can be seen in FIG. 31, the motor 100 is operably coupled to the gearassembly 820. The gear assembly 820 may include a gear box housing 822that is coupled to the motor 100. For example, the gear box housing 822may be coupled to the motor housing 101 by screws 103 or othermechanical fasteners and/or fastener arrangements. The gear assembly 820may comprise a planetary gear arrangement 821 that is operably coupledto the motor shaft 107. In one arrangement for example, a ring gear 823may be formed on the inner surface of the gear box housing 822. Aprimary sun gear 821 is coupled to the motor shaft 107. The primary sungear 821 is in meshing engagement with a plurality of first planetarygears 825 that are supported on a first planetary gear carrier 824 suchthat they are also in meshing engagement with the ring gear 823. A firstsun gear 826 is formed on or otherwise attached to the first planetarygear carrier 824 and is in meshing engagement with a plurality of secondplanetary gears 828 that are supported on a second planetary gearcarrier 827. The second planetary gears 828 are also supported inmeshing engagement with the ring gear 823. A second sun gear 829 isformed on or otherwise attached to the second planetary gear carrier 827and is in meshing engagement with a plurality of third planetary gears831. The third planetary gears 831 are supported on a third planetarygear carrier 830 and are supported in meshing engagement with the ringgear 823. A third sun gear 833 is formed on or is otherwise attached toa shaft extension 832 on the third planetary gear carrier 830 and is inmeshing engagement with a plurality of fourth planetary gears 835 thatare attached to a coupler gear that comprises a fourth planetary gearcarrier 834 that is rotatably supported on the shaft extension 832. Inaddition, a thrust bearing 836 may be journaled on the shaft extension832 between the fourth planetary gear carrier 834. The fourth planetarygears 835 are in meshing engagement with an output shaft unit 850 thatis rotatably supported by the gear box housing 822. A second thrustbearing 836 may be supported between the fourth planetary gears and theoutput shaft unit 850 as can be seen in FIG. 30. The fourth planetarygears 835 are supported in meshing engagement with an inner gear race854.

In the illustrated embodiment, the output shaft unit 850 is operablycoupled to a clutch 230 of the type and construction disclosed in Zemlok'763 which has been herein incorporated by reference in its entirety.Further details regarding the construction and operation of such clutch230 may be obtained from that publication. In an alternative embodiment,however, the clutch 230 may be replaced with a shaft-to-shaft coupler orsleeve arrangement that serves to facilitate the coupling of the outputshaft unit 850 directly to the drive tube 102.

Referring again to FIG. 31, a primary articulation drive gear 837 isattached to the articulation drive shaft 872 and is in meshingengagement with an external gear ring 838 on the fourth planetary gearcarrier 834. In various forms, the drive coupler assembly 840 mayfurther include a coupler selector member 842 that is movably coupled toor otherwise movably supported by the gear box housing 822 or otherportion of housing 812. In at least one arrangement, the couplerselector member 842 may be formed with a first drive shaft retainerportion 844 and a first articulation shaft retainer portion 846. Thefirst drive shaft retainer portion 844 comprises a grooved, roughened,etc. area that is configured to non-movably engage a second drive shaftretainer portion 845 on the output shaft unit 850. Similarly, the firstarticulation shaft retainer portion 846 comprises a grooved, roughened,etc. area that is configured to non-movably engage a second articulationshaft retainer portion 847 on the fourth planetary gear carrier 834.

Operation of the coupler assembly 840 may be understood from referenceto FIGS. 29 and 30. As can be seen in FIG. 29, the coupler selectormember 842 is pivoted to the articulation position wherein the firstarticulation shaft retainer portion 846 is in non-movable engagementwith the second articulation shaft retainer portion 847 on the outputshaft unit 850. When in that position, the output shaft unit 850 isprevented from rotating about the longitudinal axis LA-LA. Thus, when inthat position, operation of motor 100 will result in the rotation of thethird sun gear 833 which is in meshing engagement with the fourthplanetary gears 835. Rotation of the fourth planetary gears 835 willresult in the rotation of fourth planetary gear carrier 834 which canfreely rotate. Such rotation of the fourth planetary gear carrier 834will also result in the rotation of the primary articulation gear 837that is coupled to the articulation drive shaft 872. Rotation ofarticulation drive shaft 872 will cause the first articulation drivegear 873 to rotate and drive the second articulation transfer gear 874.Rotation of the second articulation transfer gear 874 results inrotation of the third articulation transfer gear and the fourtharticulation worm gear 878. Rotation of the fourth articulation wormgear 878 will drive the main articulation gear 94 which will result inthe application of axial articulation motions to the articulation links97, 70 which ultimately results in the articulation of the loading unit20 about the articulation joint. Rotation of the motor drive shaft 107in a first rotary direction will result in articulation of the loadingunit in a first articulation direction and rotation of the motor driveshaft 107 in an opposite rotary direction will result in articulation ofthe loading unit in a second articulation direction that is opposite tothe first articulation direction.

Referring next to FIG. 30, the coupler selector member 842 is pivoted tothe drive or firing position wherein the first drive shaft retainerportion 844 is in non-movable engagement with the second drive shaftretainer portion 845 on the fourth planetary gear carrier 834. When inthat position, the fourth planetary gear carrier 834 is prevented fromrotating about the longitudinal axis “LA-LA”. Thus, when in thatposition, operation of motor 100 will result in the rotation of thethird sun gear 833. Third sun gear 833 is in meshing engagement with thefourth planetary gears 835 supported on the fourth planetary gearcarrier 834. Because the fourth planetary gear carrier 834 is preventedfrom rotating by virtue of the non-movable engagement between the firstarticulation shaft retainer portion 846 and the second articulationshaft retainer portion 847 on the fourth planetary gear carrier 834,rotation of the fourth planetary gears 835 will result in rotation ofthe output shaft unit 850. Output shaft unit 850 may be coupled to thedrive tube 102 by the clutch assembly 230 or by a direct coupling. Thusrotation of the output shaft unit 850 results in rotation of the drivetube 102. As discussed above, rotation of the drive tube 102 results inthe axial movement of the firing rod (not shown in FIG. 31). Rotation ofthe motor drive shaft 107 in a first rotary direction will result in thedistal advancement of the firing rod and rotation of the motor driveshaft 107 in an opposite rotary direction will result in the proximalmovement of the firing rod. In various embodiments, closure of theloading unit 20 jaws, e.g., pivoting of the anvil assembly 22 relativeto the carrier 24, can couple and/or decouple the motor 100 to thearticulation system and/or the firing system of the surgical instrument10. For example, closure of the anvil assembly 22 relative to thecarrier 24 can decouple the motor 100 from the articulation system, e.g.from the articulation drive shaft 872, and can couple the motor 100 tothe firing system, e.g., to the output shaft unit 850. Furthermore,opening of the anvil assembly 22 relative to the carrier 24 can decouplethe motor 100 from the firing system, and can couple the motor 100 tothe articulation system. In such embodiments, the motor 100 can affectarticulation of the loading unit 20 when the loading unit 20 is open,and the motor 100 can affect firing of the firing rod when the loadingunit 20 is closed. The surgical instrument 10 can include a sensorand/or a selector, for example. In certain embodiments the sensor candetect closure of the loading unit 20 jaws. Furthermore, the sensor canbe in signal communication with the selector, such as coupler selectormember 842. The selector can couple and/or decouple the motor 100 to thearticulation system and/or the firing system when the anvil assembly 22opens and/or closes relative to the carrier 24, for example. Variouspowered surgical instruments that employ the various drive couplerarrangements disclosed herein may represent vast improvements over priorpowered surgical instruments that employ multiple motors to articulatethe end effector and fire the end effector drive member.

For example, at least one surgical instrument comprises an elongatedshaft assembly that defines a longitudinal tool axis. A surgical endeffector may be operably coupled to the elongated shaft assembly forselective articulation relative thereto. The surgical end effector maybe configured to perform at least one surgical procedure in response tofiring motions applied thereto. An articulation system may operablyinterface with the elongated shaft assembly for applying articulationmotions to the surgical end effector. A firing member assembly mayoperably interface with the elongated shaft assembly to apply the firingmotions to the surgical end effector. The surgical instrument mayfurther comprise a motor that is configured to generate rotary actuationmotions. A drive coupler assembly may interface with the motor and thearticulation system such that when the drive coupler assembly is in afirst configuration, operation of the motor will result in theapplication of the actuation motions to the articulation systemresulting in articulation of the surgical end effector relative to thelongitudinal tool axis and when the drive coupler assembly is in asecond configuration, operation of the motor will result in theapplication of actuation motions to the firing member assembly causingthe firing member assembly to apply at least one of the firing motionsto the surgical end effector.

Another surgical instrument example may comprise a handle that has anelongated shaft assembly operably coupled thereto that defines alongitudinal tool axis. A loading unit may be operably coupled to theelongated shaft assembly and be configured to sever and staple tissue inresponse to firing motions applied thereto. The loading unit may beconfigured to be selectively articulated relative to the longitudinaltool axis about an articulation joint. The surgical instrument mayfurther comprise an articulation system that includes an articulationlink assembly that is supported by the elongated shaft assembly and isconfigured to operably interface with an articulation joint portion inone of the elongated shaft assembly and the loading unit. Anarticulation actuation mechanism may be supported by the handle andinterface with the articulation link assembly to apply articulationactuation motions thereto. The surgical instrument may further comprisea firing member assembly that operably interfaces with the loading unitto apply the firing motions thereto. A motor may be operably supportedby the handle and be configured to generate rotary actuation motions. Adrive coupler assembly may interface with the motor and the articulationactuation mechanism such that when the drive coupler assembly is in afirst configuration, operation of the motor will result in theapplication of the actuation motions to the articulation systemresulting in articulation of the loading unit relative to thelongitudinal tool axis and when the drive coupler assembly is in asecond configuration, operation of the motor will result in theapplication of actuation motions to the firing member assembly causingthe firing member assembly to apply at least one of the firing motionsto the loading unit.

Still another surgical instrument example may comprise an elongatedshaft assembly that defines a longitudinal tool axis. A surgical endeffector may be operably coupled to the elongated shaft assembly forselective articulation relative thereto. The surgical end effector maybe configured to perform at least one surgical procedure in response tofiring motions applied thereto. An articulation system may operablyinterface with the elongated shaft assembly for applying articulationmotions to the surgical end effector. A firing member assembly mayoperably interface with the elongated shaft assembly to apply the firingmotions to the surgical end effector. A motor may be configured togenerate rotary actuation motions. The surgical instrument may furthercomprise means for selectively applying an output motion from the motorto each of the articulation system and the firing member assembly.

In certain motor-driven surgical instruments, a motor can provide hapticfeedback to the operator of the surgical instrument. For example,rotation of the motor can generate vibratory motion or noise, which candepend on the direction and/or speed of the motor's rotation, forexample. However, various motors may generate minimal noise, and thus,haptic feedback to the surgeon can be limited and/or may beunappreciated by the surgeon. For example, various modification and/orimprovements in motor and/or transmission design may reduce the hapticnoise generated by the motor and/or the transmission. In suchembodiments, it may be advantageous to modify the motor and/or gearassembly operably coupled to the motor to generate artificial, orintentional, haptic feedback and/or other sensory feedback. In certainembodiments, the surgical instrument can communicate the feedback to thesurgeon without requiring the surgeon to look away from the operatingsite. For example, the motor and/or gears can generate haptic and/oraudible feedback to communicate with the surgeon. In such embodiments,the operator need not look at a display screen, for example, toascertain an operating state or condition of the surgical instrument. Asdescribed in greater detail herein, the surgical instrument cancommunicate the rotational direction of the motor, for example, whichcan correspond to the firing direction of the firing member and/or thearticulation direction of the loading unit, for example. Additionally oralternatively, the surgical instrument can communicate the speed and/orthe position of the firing member during a firing stroke, for example,and/or the speed and/or degree of articulation of the loading unit, forexample.

In various embodiments, as described in greater detail herein, a motorcan be operably coupled to a firing assembly and/or an articulationassembly. Referring to FIG. 168, the motor 7010 can drive a motor shaft7014, which can engage a gear assembly 7020, for example. In variousembodiments, a key, such as key 7016 on the motor shaft 7014, can engagea portion of the gear assembly 7020. In certain embodiments, the gearassembly 7020 can include disks 7022, 7024, for example, which can bestructured to rotate or spin along with the motor shaft 7014 whenengaged therewith via a key. For example, the first disk 7022 caninclude a groove (not shown). Furthermore, a first key (not shown)extending from the motor shaft 7014 can engage the groove in the firstdisk 7022 such that the first disk 7022 rotates clockwise (CW) when themotor shaft 7014 rotates CW and rotates counterclockwise (CCW) when themotor shaft 7014 rotates CCW. In at least one embodiment, the first keycan remain engaged with the groove in the first disk 7022 throughout theoperation of the surgical instrument and/or motor thereof.

In certain embodiments, the first disk 7022 can be balanced relative toits axis of rotation along the motor shaft 7014. Referring still to FIG.168, a mass, such as mass 7026, for example, can extend from the firstdisk 7022 and may shift the center of mass of the first disk 7022 off ofthe axis of rotation of the first disk 7022. For example, the mass 7026can extend away from the motor shaft 7014 and/or away from the outerperimeter of the first disk 7022. In other words, the mass 7026 canupset the balance of the first disk 7022, result in a rotationalunbalance of the first disk 7022, and thus, generate a centrifugal forcewhen the first disk 7022 rotates with the motor shaft 7014.Consequently, rotation of the first disk 7022 and mass 7026 can generatehaptic feedback, such as a vibration or wobble of the surgicalinstrument housing and/or handle, for example. The haptic feedback cancorrespond to an operating state or condition of the surgicalinstrument. Furthermore, the haptic feedback generated by the rotationof the first disk 7022 and the mass 7026 can depend on the rotationalspeed of the motor shaft 7014. In such embodiments, the firing speedand/or the articulation speed can also be communicated to the surgeon,for example. For instance, the first disk 7022 can generate hapticfeedback having a higher frequency when the motor shaft 7014 is rotatedfaster and a lower frequency when the motor shaft 7014 is rotatedslower.

Similar to the first disk 7022, in certain embodiments, the second disk7024 can be balanced relative to its axis of rotation on the motor shaft7014. Referring still to FIG. 168, however, a mass, such as mass 7028,for example, can extend from the second disk 7024 and may shift thecenter of mass thereof. For example, the mass 7028 can extend away fromthe motor shaft 7014 and/or away from the outer perimeter of the seconddisk 7024. In other words, the mass 7028 can upset the balance of thesecond disk 7024, result in a rotational unbalance of the second disk7024, and thus, generate a centrifugal force when the second disk 7024rotates with the motor shaft 7014. Consequently, rotation of the seconddisk 7024 and mass 7028 can generate haptic feedback, such as avibration or wobble of the surgical instrument housing and/or handle,for example. The haptic feedback can correspond to an operating state orcondition of the surgical instrument. Furthermore, the haptic feedbackgenerated by the rotation of the second disk 7024 and mass 7028 candepend on the rotational speed of the motor shaft 7014. In suchembodiments, the firing speed and/or the articulation speed can also becommunicated to the surgeon, for example. In various embodiments, thefirst and/or second disks 7022, 7024 can include additional masses,similar to masses 7026 and/or 7028, for example, which can furthercontribute to a haptic response of the surgical instrument housingand/or handle, for example. Furthermore, in some embodiments, the motorshaft 7014 can operably engage additional and/or different disks of thegear assembly 7120 to selectively generate additional and/or differenthaptic feedback.

Referring still to FIG. 168, the second disk 7024 can include an innerperimeter 7026. In various embodiments, a second key 7016 can extendfrom the motor shaft 7014, and can operably engage the second disk 7024via the inner perimeter 7030. The inner perimeter 7030 can include aplurality of planar surfaces 7032 and a plurality of arcuate surfaces7034 between adjacent planar surfaces 7032, for example. Each pair ofplanar and arcuate surfaces 7032, 7034 can define a groove, which can bestructured to receive the second key 7016. In certain embodiments, whenthe key 7016 rotates in a first direction, the key 7016 can abut aplanar surface 7032 and become held and/or retained in a groove of thesecond disk 7024. In such an arrangement, the second disk 7024 canrotate in the first direction along with the motor shaft 7014.Furthermore, in certain embodiments, when the key 7016 rotates in asecond direction opposite to the first direction, the key 7016 canrotate past the arcuate surfaces 7034 and may become held and/orretained in the grooves in the inner perimeter 7030. In other words, thekey 7016 can rotate relative to the second disk 7024. In such anarrangement, the motor shaft 7014 can rotate in the second directionrelative to the second disk 7024. Accordingly, the key 7016 may onlyengage the second disk 7024 and cause the second disk 7024 to rotatewhen the motor shaft 7014 rotates in the first direction. In certainembodiments, the first direction can correspond to a CW rotation, and inother embodiments, the first direction can correspond to a CCW rotation.

As described herein, because engagement of the second disk 7024 candepend on the rotational direction of the motor shaft 7014, the seconddisk 7024 may only rotate when the motor shaft 7014 rotates in onedirection, such as when the motor 7010 drives the firing member in onedirection and/or rotates the loading unit in one direction. For example,the second disk 7024 may only rotate when the motor 7010 retracts thefiring member or rotates the loading unit CW, for example. Suchselective engagement of the second disk 7024 can affect the hapticfeedback generated by the surgical instrument. In other words, differentand/or greater haptic feedback can result based on the selectiveengagement of the second disk 7024. For example, in embodiments wherethe second disk 7024 only rotates when the motor 7010 rotates to retractthe firing member, a greater haptic feedback can be generated duringretraction than during advancement of the firing member. Duringretraction, the second disk 7024 can also contribute to the generationof haptic feedback, which can result in a greater or larger summation offeedback forces. In such embodiments, the greater haptic feedbackgenerated by the first and second disks 7022, 7024 can communicate tothe surgeon that the firing member is being retracted by the motor 7010.In various embodiments, in view of the above, only the first disk 7022may be rotated when the motor shaft 7014 is rotated in one direction andboth disks 7022, 7024 may be rotated when the motor shaft 7014 isrotated in the opposite direction. As such, the disks 7022, 7024 maygenerate different feedback when the motor shaft 7014 is rotated indifferent directions.

Referring now to FIG. 169, in certain embodiments, the motor 7010 candrive the motor shaft 7014, which can engage a gear assembly 7120. Invarious embodiments, a key, such as the key 7016 on the motor shaft7014, for example, can engage the gear assembly 7120. Similar to thegear assembly 7020, the gear assembly 7120 can include a plurality ofdisks, such as a first disk 7122 and a second disk 7124. The first andsecond disks 7122, 7124 can be structured to rotate or spin with themotor shaft 7014 when selectively engaged therewith via a key. Forexample, the first disk 7122 can include a groove (not shown). Further,a first key (not shown) extending from the motor shaft 7014 can engagethe groove of the first disk 7122 such that the first disk 7122 rotateswith the motor shaft 7014. In certain embodiments, the first key can benon-disengageable from the groove of the first disk 7122 during use. Thesecond disk 7124 can include an inner perimeter 7130, similar to theinner perimeter 7030 of second disk 7024, for example. The innerperimeter 7130 can comprise a plurality of planar surfaces 7132 and aplurality of arcuate surfaces 7134. As described herein with respect toFIG. 168, the key 7016 can selectively engage and disengage the innerperimeter 7130 of the second disk 7124 depending on the rotationaldirection of the motor shaft 7014. For example, when the motor shaft7014 rotates in a first direction, the key 7016 can engage the seconddisk 7124 causing the second disk 7124 to rotate with the motor shaft7014. Furthermore, when the motor shaft 7014 rotates in a seconddirection, the key 7016 can remain disengaged from the second disk suchthat the key 7016 can rotate relative to the second disk 7024 within theinner perimeter 7130 thereof.

In various embodiments, the first disk 7122 can include at least onepick 7126, and the second disk 7124 can also include at least one pick7128. When the disks 7122, 7124 rotate, the picks 7126, 7128 can strikeelements of an audio feedback generator 7140. For example, the picks7126, 7128 can strike clickers 7142, 7144 of the audio feedbackgenerator 7140. In various embodiments, the pick or picks 7126 of thefirst disk 7122 can strike and deflect the first clicker 7142 when thefirst disk 7122 rotates, and the pick or picks 7128 of the second disk7124 can strike and deflect the second clicker 7144 when the second disk7124 rotates. Impact and deflection of the clickers 7142, 7144 can causethe clickers 7142, 7144 to resonate and generate an auditory signal. Inother words, the rotation of the first and second disks 7122 cangenerate audio feedback. Furthermore, the rotational speed of therotating disks 7122, 7124 and/or the number and arrangement of picksextending from the first and second disks 7122, 7124 can affect thefrequency of the auditory signals. In such embodiments, the speed of themotor and corresponding firing speed of the firing element and/orarticulation of the speed of the loading unit can be communicated to thesurgeon, for example.

Referring primarily to FIGS. 170 and 171, in various embodiments, thegeometry of the picks 7126, 7128 can affect the auditory signalsgenerated by the audio feedback generator 7140. For example, the picks7126, 7128 can each include a non-dampening surface 7150 and a dampeningsurface 7152. The non-dampening surface 7152 can include a planarsurface, for example, and the dampening surface 7152 can include anarcuate surface, for example. In various embodiments, where thenon-dampening surface 7150 of the pick 7126 rotationally leads thedampening surface 7152 of the pick 7126 (FIG. 170), resonance of theclicker 7142 can be dampened and/or stopped by the trailing dampeningsurface 7152 of the pick 7126. For example, the arcuate geometry of thedampening surface 7152 may contact the deflected clicker 7126 to preventand/or restrain vibration or resonance of the clicker 7126. Conversely,where the dampening surface 7152 of the pick 7126 rotationally leads thenon-dampening surface 7150 of the pick 7126 (FIG. 171), resonance of theclicker 7142 may not be dampened by the non-dampening surface 7150 ofthe pick 7126. For example, the planar geometry of the non-dampeningsurface 7150 can avoid and/or limit contact with the deflected clicker7126 such that resonance of the clicker 7126 is permitted and/or lessrestrained. In other words, the rotational direction of the disks 7122,1724 and associated picks 7126, 7128 can affect the auditory feedbackgenerated by the surgical instrument. Accordingly, the operator of thesurgical instrument can be informed of the operating state of thesurgical instrument during its use, and without requiring the surgeon tolook away from the surgical site. For example, the audio signals can bedampened when the firing member is retracted, and may not be dampenedwhen the firing member is advanced. In other embodiments, the audiosignals can be dampened when the firing member is advanced, and may notbe dampened when the firing member is retracted. Furthermore, in someembodiments, the dampened auditory signals can correspond witharticulation of the loading unit in one direction, and the un-dampenedauditory signals can correspond with articulation of the loading unit inanother direction, for example. In various embodiments, at least oneaudio feedback generator can be used alone and/or in combination with atleast one haptic feedback system. Furthermore, in some embodiments, atleast one haptic feedback system can be used alone and/or in combinationwith at least one audio feedback generator. Audio feedback and hapticfeedback can communicate different operating conditions to the surgeonand/or can provide duplicative feedback to the surgeon regarding thesame operating conditions, for example.

In various embodiments, the surgical instrument can generate feedbackwhen the firing element approaches and/or reaches the end of the firingstroke and/or when the loading unit approaches and/or reaches thearticulation limit. In various embodiments, such feedback can bedifferent and/or additional to the feedback generated throughout afiring stroke and/or when the loading unit is articulated. Accordingly,the surgical instrument can notify the operator that the firing strokeis near completed and/or completed, for example, and/or can notify theoperator that the loading unit is near the articulation limit and/or hasreached the articulation limit.

Referring now to FIG. 172, the motor 7010 and the motor shaft 7014 canbe operably engaged with the gear assembly 7120, as described in greaterdetail above. Furthermore, the disks 7122, 7124 of the gear assembly7120 can contact an audio feedback generator 7240, which can be similarto audio feedback generator 7140, for example. For example, the picks7126, 7128 on the disks 7122, 7124 can deflect the clickers 7242, 7244of the audio feedback generator 7240 causing the clickers 7242, 7244 toresonate and generate auditory feedback. Furthermore, the audio feedbackgenerator 7240 can move or translate relative to the gear assembly 7120.As described in greater detail below, the audio feedback generator 7240can selectively move into and/or out of engagement with the clickers7242, 7244 on the disks 7122, 7124 to selectively generate auditorysignals. In other embodiments, the motor, gear assembly, and/or thedisks thereof can move, such that the picks of the disks are selectivelymoved into and/or out of engagement with the clickers of an audiofeedback generator to selectively generate auditory signals.

In various embodiments, the audio feedback generator 7240 can translatein the surgical instrument as the firing member moves during a firingstroke. For example, at the beginning of the firing stroke, the audiofeedback generator 7240 can be misaligned with the picks 7126, 7128 ofthe disks 7122, 7124. Furthermore, as the firing member moves distallyand/or approaches the end of the firing stroke, the audio feedbackgenerator 7240 can move toward and/or into alignment with the picks7126, 7128 of the disks 7122, 7124. In such embodiments, the audiofeedback generator 7240 can generate auditory feedback when the firingmember is near and/or at the end of the firing stroke. Referring to FIG.173, for example, the feedback generator can generate feedback when thefiring member is within a range of positions near and/or at the end ofthe firing stroke, for example, to communicate the position of thefiring member to the surgeon. In such embodiments, the surgicalinstrument can communicate the end of the firing stroke to the operator.For example, referring again to FIG. 172, at least one pick 7126, 7128can be aligned with at least one clicker 7242, 7244 as the firing memberapproaches the distal end of the firing stroke. At that time, thesurgical instrument can generate a feedback to communicate the positionof the firing member to the surgeon. When each pick 7126, 7128 isaligned with one of the clickers 7242, 7242, a greater and/or differentfeedback can be communicated to the surgeon. Furthermore, as the firingmember is retracted, at least one pick 7126, 7128 can again becomemisaligned with a clicker 7242, 7244 such that a reduced and/ordifferent feedback is communicated to the surgeon. Accordingly, as thefeedback generator moves through the firing stroke, the feedbackgenerator can communicate varying feedback to the operator based on theposition of the firing member. Furthermore, the gear assembly 7120 caninclude additional disks and/or picks, which can move into and/or out ofengagement with the audio feedback generator 7240, and/or the audiofeedback generator 7240 can include additional clickers, which can moveinto and/or out of engagement with the picks. In various embodiments, anaudio feedback generator can communicate alternative and/or additionalpositions of the firing member to the surgeon. For example, an audiofeedback generator can communicate auditory feedback at the midpointand/or incremental points along the length of the firing and/orretraction path.

Referring now to FIGS. 174 and 175, a movable feedback generator canalso be utilized to communicate the articulation limit of the loadingunit to the surgeon. For example, the audio feedback generator 7240depicted in FIG. 172, for example, can translate as the loading unitarticulates. For example, when the loading unit is in an unarticulatedconfiguration, the audio feedback generator 7240 can be misaligned withthe picks 7126, 7128 of the disks 7122, 7124. Furthermore, as theloading unit articulates, the audio feedback generator 7240 can movetoward and/or into alignment with the picks 7126, 7128 of the disks7122, 7124. In such embodiments, the audio feedback generator 7240 cangenerate auditory feedback when the loading unit is near and/or at thearticulation limit. For example, referring again to FIGS. 174 and 175,the feedback generator can generate feedback when the firing member iswithin a range of positions near and/or at the end of the firing stroketo communicate the position of the firing member to the surgeon. In suchembodiments, the surgical instrument can communicate the articulationlimit to the operator. For example, referring again to FIG. 172, atleast one pick 7126, 7128 can be aligned with at least one clicker 7242,7244 as the loading unit approaches its articulation limit, for example,approaches forty-five degrees. At that time, the surgical instrument cangenerate a feedback to communicate the position of the firing member tothe surgeon. When the loading unit is nearer and/or at the articulationlimit, each pick 7126, 7128 can be aligned with one of the clickers7242, 7244, and a greater and/or different feedback can be communicatedto the surgeon. Furthermore, as the loading unit is articulated backtoward the unarticulated, neutral position, at least one pick 7126, 7128can again become misaligned with a clicker 7242, 7244 such that areduced and/or different feedback is communicated to the surgeon.Accordingly, as the feedback generator moves through the firing stroke,the feedback generator can communicate varying feedback to the operatorbased on the configuration of the loading unit.

In various embodiments, it may be advantageous to protect certaincomponents of a surgical instrument from fluid contact. For example,unintentional contact with a bodily fluid during use can damage thesurgical instrument, and may limit and/or shorten the lifespan of thesurgical instrument. Furthermore, it may be advantageous to protectcertain components of a surgical instrument from fluid contact duringsterilization. For example, unintentional contact with a sterilizingand/or cleaning fluid can damage the surgical instrument, and mayprevent and/or limit the reusability of a surgical instrument. Invarious embodiments, certain components of a surgical instrument can besealed and/or protected from fluid contact. For example, electronics inthe surgical instrument can be sealed in epoxy for protection fromfluids. Moving components of the surgical instrument, such as portionsof the motor and/or the gear assembly, for example, can also be sealedand/or protected from fluid contact. Such a seal can accommodate therotation of the various moving components, for example. Furthermore, invarious embodiments, such a seal can also facilitate heat transfer suchthat the heat generated during the operation of the surgical instrumentis more effectively dissipated.

Referring now to FIGS. 185 and 186, in certain embodiments, a motor 7510and/or a gear assembly 7520 can be sealed and/or protected from fluidsduring use and/or during sterilization treatments. The motor 7510 can besimilar to the motor 100, for example, and the gear assembly 7520 can besimilar to the gear assembly 170, for example. To seal and protect themotor 7510, a motor housing, such as a rubber sleeve, for example, maybe positioned around the motor 7510 within the housing 12 (FIG. 1) ofthe surgical instrument 10 (FIG. 1). Such a rubber sleeve may limit heattransfer from the motor 7510, and the motor 7510 may be prone tooverheating. In other embodiments, referring again to FIGS. 185 and 186,the motor housing can comprise a clam-shell cover 7516, for example,which can be positioned around the motor 7510. In various embodiments,the clam-shell cover 7516 can include at least two portions, which canbe hinged and/or clasped together, for example. The clam-shell cover7516 can permit rotation of the motor 7510 and/or a motor shaft.Additionally, in certain embodiments, the clam-shell cover 7516 canfacilitate heat transfer from the motor 7510 held herein. A contactarrangement 7512 (FIG. 186), similar to the contact arrangement 210, forexample, can be employed to supply electrical current to the motor 7510.The contact arrangement 7512 can include positive and negative annularcontacts 7514 a, 7514 b (FIG. 186), for example, which can operablyconnect to fixed positive and negative contacts 7518 a, 7518 b (FIG.186) held by the clam-shell cover 7516, for example. Furthermore, theclam-shell cover 7516 can include an annular seal or gasket 7519, whichcan abut the perimeter of the motor 7510, and seal the motor 7510 andcontact arrangement 7512 within the clam-shell cover 7516, for example.In certain embodiments, the clam-shell cover 7516 can comprise ametallic material, which can facilitate heat transfer from the motor7510, for example, and may prevent overheating and/or damage to themotor 7410.

Referring still to FIGS. 185 and 186, the gear assembly 7520 can also besealed and/or protected from fluids during use and/or sterilization. Forexample, a gasket 7522 can be positioned between the motor 7510 and thehousing of the gear assembly 7520, such that the motor 7510 and gearassembly 7520 form a fluid-tight seal. Furthermore, a sealing sleeve7530 can be positioned around the housing of the gear assembly 7520. Thesealing sleeve 7530 can include a rim 7536, which can abut theclam-shell cover 7516 and/or the motor 7510 to provide a fluid-tightseal therebetween. The sealing sleeve 7530 can also include an opening7532 for an output shaft 7524. For example, the output shaft 7524 of thegear assembly 7520 can extend through the opening 7532, and fins 7534can extend toward the output shaft 7524 to provide a fluid-tight sealwhile permitting rotation of the output shaft 7524 within the opening7532. In various embodiments, the sealing sleeve 7530 and/or the rims7536, gaskets, and/or fins 7534 thereof can comprise rubber and/oranother suitable material for forming a fluid-tight seal. In variousembodiments, a mounting bracket or motor retainer 7540, similar to theretainer 190, for example, can hold the sealed gear assembly 7520 andthe motor 7510 within the housing 12 (FIG. 1) of the surgical instrument10 (FIG. 1).

FIGS. 32-37 illustrate another surgical instrument 910 that may includemany of the features of the other surgical instruments disclosed herein.In at least one form, the surgical instrument 910 may include anarticulation actuation mechanism, generally designated as 860, which maybe substantially similar to those articulation mechanisms disclosed inZemlok '763, Zemlok '344 and/or U.S. Pat. No. 7,431,188 except for thosedifferences discussed below. In other arrangements, the surgicalinstrument may include various forms of other articulation actuationmechanisms as described herein. As can be seen in FIG. 32, theinstrument 910 includes a housing 12 that may include a barrel-shapedmounting portion 90 that has rotatable member 92 mounted thereon. Therotatable member 92 interfaces with a proximal end of the elongatedshaft assembly 16 to facilitate rotation of the elongated shaft assembly16 relative to the housing 12. Such arrangement permits the clinician toselectively rotate the elongated shaft assembly 16 and the loading unit20 (or other form of surgical end effector) coupled thereto about thelongitudinal tool axis “LA-LA”. The rotatable member 92 may benon-removably mounted on the barrel portion 90 or it may be designed tobe selectively detached therefrom.

As disclosed herein, depending upon the type and/or construction of thesurgical end effector employed, it may be desirable to supply electriccurrent to the end effector. For example, the end effector may employsensor(s), light(s), actuators(s), etc. that require electricity foractivation. In such arrangements, however, the ability to rotate thesurgical end effector about the longitudinal tool axis “LA-LA” can beseverely limited because the conductor system transporting power to thesurgical end effector or loading unit through the elongated shaft from asource of electrical power may become wound up and severelydamaged—particularly in instances where the elongated shaft has beenrotated for more than one revolution. Various surgical instrumentsdisclosed herein may employ a conductor management system generallydesignated as 930 that may avoid those problems.

Referring again to FIG. 32, the surgical instrument 910 may be poweredby an electrical power source 200. The electrical power source may, forexample, be of the type described in further detail in Zemlok '763. Forexample, the electrical power source 200 may comprise a rechargeablebattery (e.g., lead-based, nickel-based, lithium-ion based, etc.). It isalso envisioned that the electrical power source 200 may include atleast one disposable battery. In at least one arrangement, for example,the disposable battery may be between about 9 volts and about 30 volts.FIG. 32 illustrates one example wherein the electrical power source 200includes a plurality of battery cells 202. The number of battery cellsemployed may depend upon the current load requirements of the instrument910. It is also conceivable that the electrical power source maycomprise a source of alternating current available in the surgicalsuite. For example, an external power cord and plug (not shown) may beemployed to transport alternating current from an outlet in the surgicalsuite to various components, conductors, sensors, switches, circuits,etc. in the surgical instrument housing and/or end effector. In otherapplications, the surgical instrument 910 may obtain power from, forexample, a robotic system to which it is attached or otherwiseassociated with.

As can be further seen in FIG. 32, the conductor management system 930may include a primary conductor member or wire 932 that is coupled to orotherwise interfaces with the electrical power source 200 for receivingpower therefrom. The primary conductor member 932 is coupled to aspiral, spool, and/or windable conductor assembly 934 that is supportedwithin the rotatable member 92. In one arrangement, for example, thespiral conductor assembly 934 may be formed or otherwise comprise aribbon-like conductor 936 that is wound in a spiral fashion in themanner depicted, for example, in FIGS. 36 and 37. For example, thespiral conductor assembly 934 may be fabricated from a spirally woundconductor that may have similar attributes to that of a spirally woundspring such as, for example, a torsion spring. In one form, for example,the conductor 936 may be wound in successive revolutions or wraps asshown in FIGS. 36 and 37. In various arrangements, the conductor 936 maybe wrapped for one or more complete revolutions. For example, theconductor 936 illustrated in FIGS. 36 and 37 is configured in more thanfour complete revolutions.

In various forms, the conductor 936 has a first end 938 that may befixed, for example, to the barrel portion 90 of the housing 12. Inaddition, the conductor 936 further has a second end 940 that isattached to or otherwise supported by the rotatable member 92 forrotational travel therewith. Thus, when the rotatable member 92 isrotated in a first rotatable direction about the barrel portion 90, thespirally wound conductor 936 is wound up in a tighter fashion.Conversely, when the rotatable member 92 is rotated in a secondrotatable direction, the degree of tightness of the spirally woundconductor 936 may be lessened. In those configurations wherein therotatable member 92 is removably supported on the barrel portion 90, thefirst end 938 of the spirally wound conductor 936 may be removablysupported in a slot or other mounting cavity 942 in the barrel portion90. See, e.g., FIGS. 36 and 37. In addition, the primary conductormember 932 may be detachably coupled to the spiral conductor assembly934 by a connector assembly 933. In particular, a detachable connectorassembly 933 may be employed to couple the primary conductor member 932to the first end of 938 of the spirally wound conductor 936 tofacilitate removal of the rotatable member 92 from the barrel portion90. In other arrangements wherein the rotatable portion 92 is notintended to be removed from the barrel portion, the first end 938 of thespirally wound conductor 936 may be non-removably affixed to the barrelportion 90 and the primary conductor member 932 may be permanentlyaffixed (e.g., soldered) to the first end of the spirally woundconductor 936.

The second end 940 of the spirally wound conductor 936 may benon-removably affixed to the rotatable member 92 by adhesive, mechanicalretainers, snap features, etc. In alternative arrangements, the secondend 940 of the spirally wound conductor 936 may be removably supportedin a slot or other mounting feature provided in the rotatable member 92to facilitate detachment of the spirally wound conductor 936 from therotatable portion 92. As can be seen in FIGS. 32 and 33, a secondaryshaft conductor member 944 is attached to the second end 940 of thespiral cable assembly 934. The secondary shaft conductor member 944 maybe supported within the rotatable member 92 and extend through thehollow elongated shaft assembly 16. For example, the secondary shaftconductor member 944 may extend through the elongated shaft assembly 16to its distal end to interface with other conductors, sensors, poweredcomponents, etc. associated with the surgical end effector, loadingunit, etc. attached thereto. Thus, when the clinician rotates therotatable member 92 relative to the housing 12, the spiral conductorassembly 934 and more particularly, the spirally wound conductor 936will wind into a somewhat tighter spiral while facilitating theapplication of power from the power source 200 to the surgical endeffector, loading unit, etc. If the clinician rotates the rotatablemember 92 relative to the housing 12 in an opposite direction, thespirally wound cable 936 will somewhat unwind while still facilitatingthe application of power from the electrical power source 200 to thevarious components, sensors, etc. on the surgical end effector, loadingunit, etc.

As can be further seen in FIGS. 34 and 35, the conductor managementsystem 930 may further include a rotation limiter assembly generallydesignated as 950. In at least one arrangement, for example, therotation limiter assembly 950 includes a limiter member 952 that ismovably attached to the rotatable member 92 and is configured tothreadably engage a threaded portion 99 on the barrel 90 of the housing12. The limiter 952 may include a pair of opposing tabs 954 that are oneach side of an axial fin portion 958 formed on the rotatable member 92as shown in FIG. 33. Such arrangement permits the limiter 952 to moveaxially within the rotatable member 92 as the rotatable member 92 isrotated on the barrel portion 90 of the housing 12. The opposite end 960of the limiter member 952 is configured to threadably engage thethreaded portion 99 of the barrel 90. An inwardly extending proximalstop wall 962 of the rotatable member 92 and an inwardly extendingdistal stop wall 964 serve to define a travel distance “TD” that thelimiter 942 may axially travel as the rotatable member 92 is rotated onthe barrel 90.

FIG. 33 illustrates the limiter 952 approximately midway between theproximal stop wall 952 and the distal stop wall 954. When in thatposition, rotation of the rotatable member 92 in a first directionrelative to the barrel portion 90 will result in the axial travel of thelimiter in the distal direction “DD” until the limiter 952 contacts thedistal stop wall 964 as shown in FIG. 34. Likewise, rotation of therotatable member 92 in an opposite direction relative to the barrelportion 90 results in the axial travel of the limiter 952 in theproximal direction “PD” until it contacts the proximal stop wall 962 ofthe rotatable member 92. Such arrangement thereby limits the number oftimes that the rotatable member 92 can be rotated completely around thebarrel portion 90 to prevent inadvertent damage of the spiral conductorassembly 934. For example, the limiter assembly 950 may enable theclinician to rotate the elongated shaft assembly and, more particularlythe rotatable member 92 for at least one full revolution but not morethan, for example, three full revolutions about the barrel portion 90 ineither direction. However, the number of revolutions, or moreparticularly, the amount of rotatable travel of the rotatable member 92on the barrel 90 may be adjusted by adjusting the magnitude of thetravel distance “TD”.

FIG. 33 illustrates the limiter 952 in a “neutral” or “central” positionwherein the limiter is centrally disposed between the distal stop wall954 and the proximal stop wall 952. In at least one form, biasingmembers 980 may be employed to bias the limiter 952 into the neutralposition when the elongated shaft assembly 16 and rotatable member 92are in a corresponding neutral position. When the clinician applies arotary motion to the rotatable portion 92, the elongated shaft assembly16 will rotate in the manner described above. However, when theapplication of the rotary motion to the rotatable member 92 andelongated shaft assembly 16 is discontinued, the biasing members 980will return the limiter 952 to the neutral position.

For example, at least one surgical instrument may comprise a housingthat may include a rotatable member that is supported on a mountingportion of the housing for rotation therearound through a range ofrotation. An elongated shaft assembly that defines a longitudinal toolaxis may be operably coupled to the rotatable member for rotationaltravel therewith about the longitudinal tool axis. The surgicalinstrument may further comprise a source of electrical power and includea conductor management system. The conductor management system maycomprise a spool conductor assembly that may be supported in therotatable member and may include a first conductor end that is fixed tothe mounting portion of the housing and a second conductor end that isfixed to the rotatable member for rotation therewith through the rangeof rotation. The conductor management system may further comprise aprimary conductor that may be supported within the housing and beconfigured to transmit electrical power from the source of electricalpower to the spool conductor assembly. A shaft conductor may be coupledto the spool conductor assembly for transmitting electrical power to adistal end of the elongated shaft assembly.

Another surgical instrument example may comprise a housing that includesa rotatable member that is supported on a mounting portion of thehousing. The surgical instrument may further comprise an elongated shaftassembly that defines a longitudinal tool axis and which may be operablycoupled to the rotatable member for rotational travel therewith aboutthe longitudinal tool axis. The surgical instrument may further comprisea source of electrical power and means for transferring power from thesource of electrical power through a conductor that extends through theelongated shaft assembly. The surgical instrument may further comprisemeans for limiting an amount of rotary travel of the rotatable memberabout the mounting portion to a range of rotary travel comprising atleast one full revolution and not more than three full revolutions aboutthe mounting portion.

As outlined herein, an end effector can be attached to a surgicalinstrument. As also outlined herein, the surgical instrument cancomprise a firing drive configured to fire staples from an end effectorincluding a staple cartridge. Turning now to the exemplary embodimentdepicted in FIG. 94, for example, a surgical instrument 9000 cancomprise a handle 9010 including a housing, a gripping portion 9012, afiring actuator 9014, and a motor positioned within the housing. Thesurgical instrument 9000 can further comprise a shaft 9040 including afiring rod 9020 which can be advanced distally and/or retractedproximally by the motor. In certain circumstances, an end effector cancomprise a distal portion which can articulate relative to a proximalportion about an articulation joint. In other circumstances, an endeffector may not have an articulation joint. The surgical instrument canfurther comprise an articulation drive configured to articulate at leasta portion of the end effector. Referring again to the exemplaryembodiment depicted in FIG. 94, for example, the surgical instrument9000 can comprise an articulation actuator 9070 which can be configuredto drive a distal portion of an end effector about an articulationjoint. The end effector depicted in FIG. 94, i.e., end effector 9060,does not happen to be an articulatable end effector; however, anarticulatable end effector could be utilized with the surgicalinstrument 9000. In the event that a non-articulatable end effector,such as the end effector 9060, for example, is used with the surgicalinstrument 9000, the operation of the articulation actuator 9070 may notaffect the operation of the end effector 9060.

Further to the above, an end effector can include drive systems whichcorrespond to the drive systems of the surgical instrument. Forinstance, the end effector 9060 can include a firing member which can beoperably engaged with the firing rod 9020 of the surgical instrument9000 when the end effector 9060 is assembled to the surgical instrument.Similarly, an end effector can comprise an articulation driver which canbe operably engaged with an articulation rod of the surgical instrumentwhen the end effector is assembled to the surgical instrument.Furthermore, the end effector 9060, for example, can comprise a proximalconnection portion 9069 which can be mounted to a distal connectionportion 9042 of the shaft 9040 of the surgical instrument 9000 when theend effector 9060 is attached to the surgical instrument 9000. Invarious circumstances, the proper assembly of the connection portions,the drive system, and the articulation system of an end effector and asurgical instrument may be required before the end effector can beproperly used.

Referring again to FIG. 94, the handle 9010 can comprise a firingtrigger 9014 which, when actuated by the user of the surgical instrument9000, can be configured to operate the motor in the handle 9010. Invarious circumstances, the handle 9010 can include a controller whichcan be configured to detect the actuation of the firing trigger 9014. Insome instances, the actuation of the firing trigger 9014 can close anelectrical circuit in signal communication with the controller. In suchinstances, the controller can be configured to then operate the motor toadvance the firing rod 9020 distally and move a jaw 9062 of the endeffector 9060 toward a jaw 9064. In some circumstances, the handle 9010can include at least one sensor which can be configured to detect theforce applied to the firing trigger 9014 and/or the degree to which thefiring trigger 9014 is moved. The sensor, or sensors, can be in signalcommunication with the controller, wherein the controller can beconfigured to adjust the speed of the motor based on one or more inputsignals from the sensors. The handle 9010 can comprise a safety switch9015 which may need to be depressed before the controller will operatethe motor in response to input from the firing trigger 9014. In variouscircumstances, the safety switch 9015 can be in signal communicationwith the controller wherein the controller can electronically lockoutthe use of the motor until the safety switch 9015 is depressed. Thehandle 9010 may also comprise a retraction actuator 9074 which, whenactuated, can cause the motor to be operated in an opposite direction toretract the firing rod 9020 and permit the jaw 9062 to move away fromthe jaw 9064. In various circumstances, the actuation of the retractionactuator 9074 can close an electrical circuit in signal communicationwith the controller. In some instances, the safety switch 9015 may needto be depressed before the controller will operate the motor in itsreverse direction in response to input from the retraction actuator9074.

Prior to and/or during the use of the surgical instrument 9000, thesurgical instrument 9000 and/or certain systems of the surgicalinstrument 9000 may become inoperative, maloperative, and/or defective.In certain circumstances, such deficiencies, and/or the manner by whichto resolve them, may not be readily apparent to the user of the surgicalinstrument which can cause the user to become frustrated. Moreover, suchuncertainties can increase the time needed to address the deficiency, or“error”. The surgical instrument 9000 is an improvement over theforegoing. Referring again to FIG. 94, the controller of the surgicalinstrument 9000 can be configured to detect an error of the surgicalinstrument 9000 and communicate that error to the user of the surgicalinstrument 9000 via one or more indicators. The surgical instrument 9000can comprise one or more indicators which, when activated by thecontroller, can indicate the nature of the error and/or otherwise directtheir attention to the system of the surgical instrument 9000 that isdeficient in some way. For instance, the surgical instrument 9000 cancomprise an end effector indicator 9086 which can be, for example,configured to indicate that an end effector has not been assembled tothe shaft 9040 of the surgical instrument 9010. In variouscircumstances, the surgical instrument 9000 can comprise a sensor whichcan be configured to detect when an end effector has been assembled tothe shaft 9040 and/or, correspondingly, when an end effector has notbeen assembled to the shaft 9040. The sensor can be in signalcommunication with the controller such that the controller can receive asignal from the sensor and ascertain whether or not an end effector hasbeen assembled to the shaft 9040. In the event that the controllerascertains that an end effector has not been assembled to the shaft9040, the controller can actuate the end effector indicator 9086. Invarious circumstances, the end effector indicator 9086 can comprise alight, such as a red light, for example. In some circumstances, the endeffector indicator 9086 can comprise a light emitting diode, such as ared light emitting diode, for example. In addition to or in lieu of theabove, the surgical instrument 9000 can comprise a sensor in signalcommunication with the controller which can be configured to detect whenthe end effector attached to the shaft 9040 has been previously used.For instance, such a sensor could be configured to ascertain that atleast some of the staples stored within the end effector have been firedand/or that a staple firing member within the end effector has beenpreviously advanced. In such instances, the controller can actuate theend effector indicator 9086. Thus, the activation of the end effectorindicator 9086 can signal to the user of the surgical instrument 9000that some error exists with regard to the end effector and that sucherror should be, or must be, addressed prior to operating the surgicalinstrument 9000. The reader will appreciate from FIG. 94 that the endeffector indicator 9086 is adjacent to the distal end of the shaft 9040and, in various circumstances, can be located on, or near, the distalconnection portion 9042 of the shaft 9040. In various circumstances, theend effector indicator 9086 could be located on the end effector 9060.In any event, when the end effector indicator 9086 is illuminated, as aresult of the above, the user of the surgical instrument 9000 canquickly ascertain that an error exists and that error pertains to theend effector in some way. The illumination of the end effector indicator9086 can indicate to the user that the assembly of the end effector tothe shaft 9040 may be incomplete and/or that the end effector may needto be replaced.

In addition to or in lieu of the end effector indicator 9086, a surgicalinstrument can comprise one or more indicators. For instance, thesurgical instrument 9000 can comprise a firing trigger indicator 9081.The firing trigger indicator 9081 can be in signal communication withthe controller of the surgical instrument 9000 such that, when thecontroller detects an error related to the firing drive of the surgicalinstrument 9000, for example, the controller can activate the firingtrigger indicator 9081. As illustrated in FIG. 94, the firing triggerindicator 9081 can be positioned adjacent to the firing trigger 9014. Insuch circumstances, the user of the surgical instrument 9000, uponobserving the actuation of the firing trigger indicator 9081, may deducethat an error has occurred related to the firing drive and may begin todiagnose the source of the error. In some circumstances, the controllermay activate the firing trigger indicator 9081 when the battery of thesurgical instrument 9000 has become defective in some way, for example.For instance, if the voltage of the battery is below a desirable level,the battery may not be able to operate the motor in a desired manner andthe firing trigger indicator 9081 may indicate the need to replace thebattery, for example. In various circumstances, the controller cancurrently render one or more operating systems of the surgicalinstrument 9000 inoperative when the controller illuminates anindicator, such as the end effector indicator 9086 and/or the firingtrigger indicator 9081, for example. For instance, the controller can beconfigured to operably decouple the firing trigger 9014 from the motorsuch that the actuation of the firing trigger 9014 does not operate themotor when the end effector indicator 9086 and/or the firing triggerindicator 9081 is illuminated, for example. Such an operative decouplingof the firing trigger 9014 from the motor can also indicate to the userof the surgical instrument 9000 that the surgical instrument may haveexperienced an error and that the user should review the indicators ofthe surgical instrument 9000 to ascertain the nature of that error.

Referring again to the exemplary embodiment of FIG. 94, the surgicalinstrument 9000 can comprise a retraction actuator indicator 9085positioned adjacent to the retraction actuator 9074. Similar to theabove, the retraction actuator indicator 9085 can be in signalcommunication with the controller wherein, in the event the controllerdetects an error in connection with the retraction drive, for example,the controller can illuminate the retraction actuator indicator 9085. Invarious circumstances, the controller can illuminate the retractionactuator indicator 9085 in the event that the safety switch 9015 is notdepressed prior to actuating the retraction actuator 9074. In suchcircumstances, the retraction actuator indicator 9085 can serve as areminder to depress the safety switch 9015. In certain circumstances,the surgical instrument 9000 can comprise a safety switch indicator 9082positioned adjacent to the safety switch 9015. In some circumstances,the controller of the surgical instrument 9000 can illuminate the safetyswitch indicator 9082 when the user actuates the retraction actuator9074 before actuating the safety switch 9015. The safety switchindicator 9082 can be in signal communication with the controllerwherein, in the event that the controller detects that the firing systemcannot be switched between a firing mode and a retraction mode, forexample, the controller can illuminate the safety switch indicator 9082.The surgical instrument 9000 can comprise an articulation actuatorindicator 9084 positioned adjacent to the articulation actuator 9070.Similar to the above, the articulation actuator indicator 9084 can be insignal communication with the controller wherein, in the event thecontroller detects an error in connection with the articulation drive,for example, the controller can illuminate the articulation actuatorindicator 9084. The surgical instrument 9000 can comprise a shaftindicator 9083 positioned adjacent to a shaft connection configured toattach the shaft 9040 to the handle 9010. Similar to the above, theshaft indicator 9083 can be in signal communication with the controllerwherein, in the event the controller detects an error in connection withthe shaft 9040, for example, the controller can illuminate the shaftindicator 9083.

Turning now to FIG. 95, a surgical instrument 9100 can include a handle9110 including an array of indicators 9190 configured and operated toindicate to the user of the surgical instrument 9100 that one or moreerrors may exist with regard to the surgical instrument 9100 and/or theend effector attached thereto. The array of indicators 9190 can bearranged in any suitable manner. In various circumstances, the array ofindicators 9190 can be arranged in the shape of, or the approximateshape of, the surgical instrument 9100 and/or an end effector attachedthereto, for example. In at least one instance, the outer surface of thehandle 9110, for example, can include a representation of the surgicalinstrument 9100 and/or the end effector attached to the surgicalinstrument. The array of indicators 9190 can be arranged relative to anoutline of the surgical instrument and the end effector in a mannerconfigured to convey the portion of the surgical instrument 9100 and/orend effector which is experiencing an error, has experienced an error,and/or may need to be evaluated to address an error, for example. Forinstance, the outline can be demarcated to depict the end effector 9060,the shaft 9040, the handle 9010, the firing trigger 9014, the safetyswitch 9015, the reverse actuator 9074, and/or the articulation actuator9070. In various circumstances, an end effector indicator 9192 can bepositioned adjacent the depiction of the end effector 9060, a shaftindicator 9193 can be positioned adjacent the depiction of the shaft9040, a firing trigger indicator 9191 can be positioned adjacent thedepiction of the firing trigger 9014, a safety switch indicator 9195 canbe positioned adjacent the depiction of the safety switch 9015, areverse actuator indicator 9196 can be positioned adjacent the depictionof the reverse actuator 9074, and/or an articulation actuator indicator9194 can be positioned adjacent the depiction of the articulationactuator 9070, for example. In various circumstances, each of theindicators 9191, 9192, 9193, 9194, 9195, and/or 9196 can comprise alight emitting diode. In some circumstances, each light emitting diodecan comprise a red light emitting diode which can be illuminated by thecontroller to indicate the presence of an error. In variouscircumstances, the controller can be configured to pulse theillumination of a light emitting diode which may decrease the timeneeded for the user to realize that an indicator has been illuminated.In certain circumstances, each indicator can include a light emittingdiode which can emit more than one color. In some circumstances, eachsuch light emitting diode can be configured to selectively emit a redcolor and a green color, for example. The controller can be configuredto illuminate the light emitting diode with the green color if no erroris not detected with regard to the associated portion of the surgicalinstrument 9100 and/or end effector attached thereto or, alternatively,with the red color if an error is detected with regard to the associatedportion of the surgical instrument 9100 and/or the end effector attachedthereto.

In some circumstances, as described in greater detail further below, thecontroller of the surgical instrument 9000 can lock out one or more ofthe actuators of the surgical instrument, such as firing trigger 9014,retraction actuator 9074, and/or articulation actuator 9070, forexample, when the controller illuminates an indicator associated withthat actuator. For instance, the controller can lock out the firingtrigger 9014 when it illuminates the firing trigger indicator 9081, theretraction actuator 9074 when it illuminates the retraction actuatorindicator 9085, and/or the articulation actuator 9070 when itilluminates the articulation actuator indicator 9084. The handle 9010 ofthe surgical instrument 9000, for example, can comprise a firing triggerlock which can be configured to selectively ‘lock out’ the firingtrigger 9014 and prevent the firing trigger 9014 from being actuated.The firing trigger lock can prevent the firing trigger 9014 from beingsufficiently actuated to operate the motor of the surgical instrument.In at least one such circumstance, the firing trigger 9014 can beprevented from closing a firing trigger switch. In certaincircumstances, the controller of the surgical instrument 9000 can beconfigured such that it electronically locks out the firing trigger9014, i.e., prevents battery power from being supplied to the motor, inaddition to actuating the firing trigger lock. In such circumstances,the electronic lock out and the mechanical lock out may be redundant;however, the mechanical lock out can provide feedback to the user of thesurgical instrument 9000 that the firing drive has been operablydeactivated. As mentioned above, the controller of the surgicalinstrument 9000 can also provide feedback via the firing triggerindicator 9081, for example. In such a way, a user of the surgicalinstrument 9000 can be provided with tactile feedback and/or visualfeedback that an error has occurred. In some circumstances, the tactilefeedback may prompt the user of the surgical instrument 9000 to beginsearching for the visual feedback. For instance, the user may attempt toactuate the firing trigger 9014 and, upon being unable to actuate thefiring trigger 9014, the user may then review the instrument forilluminated indicators. In any event, once the error has been resolved,the controller can unlock the firing trigger 9014 by deactivating thefiring trigger lock.

Turning now to FIG. 100, the surgical instrument 9000 can include afiring trigger lock 9390 which can be configured to lock out the firingtrigger 9014. The firing trigger lock 9390 can be movable between alocked condition, illustrated in FIGS. 100, 101, and 103, and anunlocked condition, illustrated in FIG. 102. When an end effector is notassembled to the shaft 9040 of the surgical instrument 9000, the firingtrigger lock 9390 can be biased into its locked condition. In thislocked condition, the firing trigger lock 9330 can block, or at leastsubstantially block, the actuation of the firing trigger 9014. Moreparticularly, the firing trigger lock 9390 can include a shaft rack9391, a pinion 9392, and a handle rack 9393, and a biasing member, suchas a spring, for example, which can be configured to bias the shaft rack9391 into a proximal position and the handle rack 9393 into a downwardposition. The proximal position of the shaft rack 9391 and the downwardposition of the handle rack 9393 are illustrated in FIG. 101. Referringprimarily to FIG. 101, the handle rack 9393 can include apertures 9396and the firing trigger 9014 can include projections 9395 which, when thehandle rack is in its downward position, are not aligned with theapertures 9396. More specifically, the firing trigger 9014 can comprisea rocker switch including a fulcrum 9397 wherein, when the handle rack9393 is in its downward position, rocking of the firing trigger 9014will cause at least one of the projections 9395 extending from thefiring trigger 9014 to abut the handle rack 9393 and prevent the firingtrigger 9014 from being completely actuated.

When an end effector is attached to the shaft 9040, further to theabove, the firing trigger lock 9390 can be moved between its lockedconfiguration and its unlocked configuration. In the unlockedconfiguration of the firing trigger lock 9390, referring primarily toFIG. 102, the handle rack 9393 can be in its upward position. In theupward position of the handle rack 9393, the apertures 9396 defined inthe handle rack 9393 are aligned with the projections 9395 extendingfrom the firing trigger 9014. In such circumstances, the firing trigger9014 can be rocked to actuate the firing trigger 9014. Morespecifically, the projections 9395 can pass through the apertures 9396to permit the rocking of the firing trigger 9014 about the fulcrum 9397.Thus, in view of the above, the movement of the handle rack 9393 betweenits downward and upward positions respectively locks and unlocks thefiring trigger 9014. Various mechanisms can be utilized to move thehandle rack 9393 between its downward position and its upward position.In at least one such embodiment, referring again to FIG. 100, the shaft9040 can include a firing lock actuator 9399 which can be displacedproximally by an end effector when the end effector is assembled to theshaft 9040. The shaft rack 9391 can be mounted and/or extend proximallyfrom the firing lock actuator 9399 and can include teeth 9391 a definedthereon. The teeth 9391 a can be meshingly engaged with teeth 9392 adefined on pinion gear 9392 such that, when the firing lock actuator9399 and the shaft rack 9391 are displaced proximally, the pinion gear9392 can be rotated about an axis. Correspondingly, the handle rack 9393can comprise rack teeth 9393 a defined thereon which are also meshinglyengaged with the pinion gear teeth 9392 a and, thus, when the shaft rack9391 is driven proximally, the handle rack 9393 can be driven from itsdownward position into its upward position thereby unlocking the firingtrigger 9014. In order to return the handle rack 9393 to its downwardposition, the shaft rack 9391 can be moved distally to rotate the piniongear 9392 in the opposite direction. In various circumstances, the shaftrack 9391 can move distally as a result of an end effector beingdisassembled from the shaft 9040.

Turning now to FIGS. 96-97, handle 9010, for example, can include atrigger lock 9290. The trigger lock 9290 can comprise a housing 9291, adeployable lock pin 9292, a retainer 9293, and a biasing member 9294configured to move the lock pin 9294 between an undeployed position,illustrated in FIGS. 96 and 98 and a deployed position, illustrated inFIGS. 97 and 99. In various instances, the retainer 9293 can becomprised of a temperature sensitive material which is affected by heat.In at least one such instance, the temperature sensitive material can beconfigured to transition between a solid and a fluid, such as a liquid,suspension, and/or gas, for example, and/or between a solid material andsemi-solid material, for example. When the temperature sensitivematerial transitions, or at least partially transitions, between a solidand a fluid, the retainer 9293 can release the lock pin 9294 to lock thefiring trigger, and/or any other suitable trigger, of the handle 9010.In various instances, the lock pin 9294, when deployed, can slide behindand/or otherwise engage the firing trigger. A handle can include anysuitable number of trigger locks 9290, or the like, to selectively lockout any suitable number of triggers and/or buttons, for example. As thereader will appreciate, the trigger lock 9290 may not be resettable. Insuch instances, an actuated trigger lock 9290 may permanently lock outthe firing trigger, for example, of the handle such that the instrumentmay no longer be used. A permanent lock out of the firing trigger,and/or any other trigger, of the instrument may mean that the instrumentmay no longer be usable whatsoever while, in other circumstances, thepermanent lock out may not be readily resettable and may require theinstrument to be sent to a qualified technician, or facility, forexample, who can assess whether the instrument should be reconditionedand reused or whether the instrument should be disposed of. When theheat sensitive material of the retainer 9293 has been at least partiallyconverted to a fluid, it may be assumed by the technician that theinstrument was exposed to a temperature which exceeded the transitiontemperature of the heat sensitive material. In various instances, thetransition temperature of the heat sensitive material can be thetemperature in which the solid material, for example, liquefies,evaporates, and/or sublimates, for instance. In any event, the heatsensitive material, and, hence, the transition temperature, of theretainer 9293 can be selected such that the release of the lock pin 9294can indicate that the surgical instrument has been exposed to atemperature which exceeds a certain, or threshold, temperature. Invarious instances, a surgical instrument can be damaged if it is exposedto an excessive temperature. For instance, the surgical instrument caninclude solid state electronics, for example, which can be damaged whenexposed to such an excessive temperature. In such instances, thethreshold temperature of the instrument and the transition temperatureof the retainer 9293 can be equal, or at least substantially equal,wherein, as a result, it can be assumed that the instrument has not beenexposed to a temperature which exceeds the threshold temperature whenthe trigger lock 9290 has not been actuated and, correspondingly, thatthe instrument has been exposed to a temperature which exceeds thethreshold temperature when the trigger lock 9290 has been actuated and,as such, the surgical instrument may have been damaged, or may at leastrequire an evaluation as to whether it has been damaged.

Further to the above, a surgical instrument may be exposed totemperatures which exceed the threshold temperature and/or thetransition temperature when the surgical instrument is sterilized. Manysterilization procedures are known, several of which include the step ofexposing the surgical instrument to heat. In addition to or in lieu ofthe trigger lock 3290, a surgical instrument can include at least onetemperature sensor which can evaluate the temperature in which thesurgical instrument is exposed to. In various instances, the temperaturesensor, or sensors, can be in signal communication with a controller ofthe surgical instrument which can be configured to assess whether thesurgical instrument has been exposed to a temperature which exceeds thethreshold temperature. In at least one such instance, the controller caninclude a microprocessor and an algorithm which can evaluate the signalsreceived from the temperature sensor, or sensors. In the event that thecontroller determines that the threshold temperature has been reachedand/or exceeded, the controller can permanently prevent the instrumentfrom being operated. Stated another way, the controller can apply anelectronic lock out to the surgical instrument. Similar to the above, apermanent lock out of the instrument may mean that the instrument may nolonger be usable whatsoever while, in other circumstances, the permanentlock out may not be readily resettable and may require the instrument tobe sent to a qualified technician, or facility, for example, who canassess whether the instrument should be reconditioned and reused orwhether the instrument should be disposed of. As the reader willappreciate, a power source may be needed to operate the controllerand/or sensors of the surgical instrument while the surgical instrumentis being sterilized. Several embodiments of surgical instruments includea removable battery, or power source, which is removed prior tosterilizing the surgical instrument wherein, in such instances, theremovable battery is sterilized and/or reprocessed separately. Once theremovable power source has been removed from these previous instruments,as the reader will appreciate, the controller and/or sensors may nothave sufficient power to monitor the temperature of the surgicalinstrument. Embodiments of surgical instruments disclosed herein caninclude a battery, or power source, which is not removed from thesurgical instrument when it is reprocessed. Such a battery may bereferred to as a permanent battery as it may supply power to thecontroller and/or temperature sensors while the instrument is beingsterilized. In various instances, an instrument including a permanentbattery may also include a removable and/or rechargeable battery. In anyevent, the instrument may have sufficient power to detect and record thetemperature that the instrument is exposed to. In at least one instance,the controller of the instrument can include a memory chip configured tostore the temperature readings, such as in a temperature register, forinstance. In various circumstances, the controller can record readingsfrom the sensors intermittently, i.e., at an appropriate sampling rate.In some instances, the controller can be configured such that, when itrecords a temperature reading above a certain temperature, albeit belowthe threshold temperature, the controller can increase the samplingrate. Correspondingly, the controller can be configured such that, whenit subsequently records a temperature reading below the certaintemperature, the controller can decrease the sampling rate, such as backto its original sampling rate, for instance.

Turning now to FIG. 99A, an algorithm for the controller is depicted. Incertain instances, this algorithm can comprise a start-up procedure forthe surgical instrument such as when the surgical instrument is firstused after it has undergone a sterilization process, for instance. Thestart-up procedure can commence after the instrument has been turned on.The instrument can be automatically turned on when an end effector isassembled to the instrument. In at least one such instance, the assemblyof the end effector to the surgical instrument can close a switch insignal communication with the controller. In addition to or in lieu ofthe above, the instrument can be turned on when a button and/or switchis depressed on the handle, for example. In any event, the controllercan then evaluate temperature readings stored in the memory chip,discussed above. For instance, the controller can evaluate whether anyof the stored temperature readings are equal to or greater than thethreshold temperature. If the controller determines that all of thestored temperature readings are below the threshold temperature, thecontroller can proceed with its normal startup procedure. If thecontroller determines that one or more stored temperature readings areequal to or exceed the threshold temperature, the controller can proceedwith an alternate procedure. In at least one instance, the controllercan permanently disable the instrument such as by implementing anelectronic lockout and/or a mechanical lockout, as discussed elsewherein this application. In certain other instances, the controller canpermit the instrument to be used eventhough the controller hasdetermined that one or more stored temperature readings is equal to orexceeds the threshold temperature. The controller can store thatdetermination in its memory and/or indicate to the user through adisplay, such as a light emitting diode, for example, that the thresholdtemperature had been previously exceeded and then proceed with itsnormal startup procedure. In various instances, the controller can treatthe threshold temperature as an absolute maximum, i.e., a singletemperature reading at or above the threshold temperature is sufficientto trigger an alternative startup program or permanently lockout theinstrument. In other instances, the controller can be configured toevaluate whether a pattern of temperature readings at or above thethreshold temperature is sufficient to trigger an alternative startupprogram or permanently lockout the instrument as both time andtemperature may be factors to consider whether an instrument has beencompromised from a sterilization procedure, for example.

Turning now to FIGS. 104-109, a surgical instrument, such as thesurgical instrument 9000, for example, can include a handle 9410including a firing trigger lock system 9490. The handle 9410 can besimilar to the handle 9110 in many respects and such respects are notrepeated herein for the sake of brevity. Similar to the above, thefiring trigger lock system 9490 can be configured to lock and unlock afiring trigger 9414. Also similar to the above, the firing trigger locksystem 9490 can be biased into a locked condition when an end effectoris not assembled to the shaft 9040 of the surgical instrument, asillustrated in FIGS. 104-107, and moved into an unlocked condition whenan end effector is fully assembled to the shaft 9040, as illustrated inFIGS. 108 and 109. When an end effector is assembled to the shaft 9040,further to the above, referring primarily to FIGS. 108 and 109, the endeffector can push the sensing member 9499 proximally. The sensing member9499 can extend through the shaft 9040 from a distal end of the shaft9040 to a proximal end thereof. In use, the end effector can abut thedistal end of the sensing member 9499 when the end effector is assembledto the shaft 9040 and push the sensing member 9499 proximally, asoutlined above. When the sensing member 9499 is pushed proximally, asillustrated in FIGS. 108 and 109, the sensing member 9499 can contact aswing arm 9486 of the firing trigger lock system 9490 and rotate theswing arm 9486 upwardly. The swing arm 9486 can comprise an endpivotably mounted to the handle housing via a pin 9487 which isconfigured to permit the swing arm 9486 to rotate about an axis. Theswing arm 9486 can further comprise a cam follower portion 9488 whichcan be contacted by the sensing member 9499. In use, the sensing member9499 can move the swing arm 9486 between a downward position and anupward position in order to move the firing trigger lock system 9490between a locked position and an unlocked position, respectively. Thefiring trigger lock system 9490 can further include a lock pin 9485mounted to the swing arm 9486 which can be pulled upwardly when theswing arm 9486 is rotated upwardly and, correspondingly, pusheddownwardly when the swing arm 9486 is rotated downwardly. The lock pin9485 can comprise an upper end pivotably mounted to the swing arm 9486and a lower end that extends through an aperture 9483 defined in thefiring trigger 9481 when the lock pin 9485 is in its downward position.In various circumstances, the aperture 9483 can be defined in an arm9482 extending from the firing trigger 9414. When the lock pin 9485 ispositioned within the aperture 9483, the firing trigger 9414 may not bepivoted about its fulcrum 9484 and, as a result, the firing trigger 9414may not be actuated by the user. When the lock pin 9485 is in its upwardposition, the lock pin 9485 may not be positioned within the aperture9483 and, as a result, the firing trigger 9414 may be actuated by theuser. When the end effector is disassembled from the shaft 9040, thesensing member 9499 can be moved from its proximal position to itsdistal position. Stated another way, without an end effector attached tothe shaft 9040, a biasing member, such as spring 9489, for example, canbias the swing arm 9486 downwardly and, accordingly, bias the firingtrigger lock system 9490 into its locked condition. Moreover, the spring9489 can apply a biasing force to the sensing member 9499 through thearm 9482 and push the sensing member 9499 distally when an end effectoris not assembled to the shaft 9040.

Further to the above, the operation of the sensing member 9499 and thefiring trigger lock system 9490 can serve to communicate with the userof the surgical instrument. For instance, when an end effector is notassembled to the shaft 9040, the sensing member 9499 is biased distallyand the firing trigger 9414 will be locked out wherein, if the user wereto attempt to actuate the firing trigger 9414, the user would quicklyrealize that something may be wrong with the firing system of thesurgical instrument. In this example, the user would quickly realizethat an end effector needs to be assembled to the shaft 9040 in order touse the surgical instrument. In various circumstances, the firingtrigger could be locked out if an end effector, although attached to theshaft 9040, had been used. In at least one such circumstance, the endeffector could include a firing member which, when positioned in itsproximal-most position, could push a sensing member proximally when theend effector is assembled to the shaft 9040; however, if such a firingmember has already been at least partially advanced when the endeffector is assembled to the shaft 9040, the sensing member may not bepushed proximally and, as a result, the firing trigger may remain lockedout. Again, such a firing trigger lock out can communicate to the userthat a problem exists with the firing drive; namely, in thiscircumstance, that the end effector has already been used. Absent such atactile lockout, the user would experience circumstances in which theyare able to depress an actuator without the surgical instrumentresponding to the depressed actuator thereby possibly leading to theconfusion of the user.

As discussed above, the assembly of a previously-unfired end effector tothe shaft 9040 can push a sensing member proximally to unlock the firingtrigger. In various circumstances, the sensing member and the firingtrigger lock system can be configured such that the firing trigger isnot unlocked until the end effector is completely assembled to the shaft9040. In the event that the end effector is only partially assembled tothe shaft 9040, the sensing member may not be sufficiently displaced tounlock the firing trigger. Again, such a firing trigger lockout cancommunicate to the user that a problem exists with the firing drive;namely, in this circumstance, that the end effector has not beencompletely assembled to the shaft 9040.

As described herein, an end effector can be assembled to surgicalinstrument which can include a controller configured to identify the endeffector. In some instances, the controller can be configured to assessthe identity of the end effector when the controller is activated. Incertain instances, turning now to FIG. 176, the controller can beactivated when a battery is inserted into the handle. In addition to orin lieu of the above, the controller can be configured to assess thecondition of the surgical instrument when the controller is activated.For example, the controller can be configured to assess the position ofthe closure member of the closing system, the position of the firingmember of the firing system, and/or the position of the articulationmember of the articulation system. In certain instances, the surgicalinstrument can include an absolute positioning sensor to detect theposition of the firing member. Such a sensor is disclosed in U.S. patentapplication Ser. No. 13/803,097, entitled ARTICULATABLE SURGICALINSTRUMENT COMPRISING A FIRING DRIVE, which was filed on Mar. 14, 2013,the entire disclosure of which is incorporated by reference herein. Insome instances, the surgical instrument can include an end of strokeregister. Such an end of stroke register can comprise a mechanicalswitch, counter, and/or toggle and/or an electronic switch, counter,and/or toggle including data stored in nonvolatile memory. In such anembodiment, the controller can assess whether the previous firing strokehad been completed. Such embodiments can be helpful in a multitude ofsituations. For instance, the controller may be accidentally shut off orotherwise lose power during a surgical procedure and, when thecontroller is reactivated, the controller may not be able to assesswhether the instrument is being initialized for the first time orwhether the instrument was in the middle of a previous firing stroke.The end of stroke register can assist the controller in discerningbetween these two events. Moreover, an end of stroke of register that isnot lost or reset by a power loss or interruption to the instrument canallow the controller to assess whether the surgical instrument had lostpower during a firing stroke. If the controller determines that theprevious firing stroke had not been completed, the controller can beconfigured to, one, permit power to be supplied to the motor to finishthe firing stroke and/or, two, permit power to be supplied to the motorto retract the firing member, the closure member, and/or thearticulation member to their home, or unactuated, positions. In variousinstances, the controller can provide the user of the surgicalinstrument with the option of proceeding with the firing stroke orreturning the mechanical systems and/or electrical systems of theinstrument to their original, or unactuated, positions. In suchembodiments, the surgical instrument may not automatically return thesesystems to their original, or unactuated, positions. In any event, oncethe surgical instrument is in its home, or unactuated, condition, apreviously fired end effector can be disassembled from the surgicalinstrument and/or an unfired end effector can be assembled to thesurgical instrument. In various instances, as outlined herein, thesurgical instrument can then identify, or at least attempt to identify,the unfired end effector.

Turning now to FIG. 177, a controller of a surgical instrument canperform a diagnostic check of the instrument and/or battery. Forinstance, upon activation of the controller, the surgical instrument canevaluate whether the surgical instrument had been exposed to atemperature beyond the threshold temperature of the surgical instrument,as described herein. Also, for instance, the surgical instrument canevaluate the available power, voltage, and/or current of the battery, asalso described herein. If the instrument fails one or more of thesediagnostic tests, the controller may not supply power to the motor,physically lockout the instrument, and/or indicate such failure to theuser of the surgical instrument. In such circumstances, the instrumentmay record such failures in its memory so that the test data may assista technician in later evaluating the instrument. Assuming that theinstrument passes these diagnostic tests, the instrument, similar to theabove, may also record the test data associated with passing thediagnostic tests. In any event, the instrument may then proceed toevaluate whether the instrument is in a home, or unactuated, conditionand assess the identity of the end effector. As outlined herein, aprocedure for identifying the end effector is disclosed. Also disclosedherein is a procedure for assessing whether a ‘smart’ end effector or a‘dumb’ end effector is attached to the surgical instrument. In variousinstances, a ‘smart’ end effector can be an end effector which cansupply parameters and/or at least a portion of an operating program tothe surgical instrument as part of the identification process. A ‘smart’end effector can be an end effector which somehow identifies the mannerin which the end effector is to be used by the surgical instrument. Incertain instances, a ‘dumb’ end effector is an end effector which doesnot identify the manner in which it is to be used with the surgicalinstrument in any way. An exemplary operating procedure in accordancewith the above is outlined in FIG. 178.

As discussed herein, a battery can be utilized to power a surgicalinstrument. In various instances, the surgical instrument and/or batterycan be configured to assess whether the battery can supply sufficientpower to the surgical instrument to perform one or more functions. Incertain instances, the surgical instrument and/or the battery can beconfigured to indicate to the user of the surgical instrument that thebattery has sufficient power to perform one or more functions. FIG. 179depicts a circuit configured to indicate the voltage of a battery. Sucha circuit can be present in the surgical instrument and/or the battery.In either event, a circuit can include a plurality of indicators whichcan be indicative of the charge, voltage, and/or power that can besupplied by the battery. For instance, the circuit can include threeindicators including a first indicator configured to indicate that thebattery includes at least a first voltage, a second indicator configuredto indicate that the battery includes at least a second voltage, and athird indicator configured to indicate that the battery includes atleast a third voltage. As illustrated in FIG. 179, a circuit 12100 caninclude a first indicator circuit 12110, a second indicator circuit12120, and a third indicator circuit 12130 which are arranged inparallel with one another. When switch 12101 is closed, a voltagepotential from the battery can be applied across the indicator circuits12110, 12120, and 12130. The first indicator circuit 12110 can include aZener diode 12111, a light emitting diode 12112, and a resistor R112113. Similarly, the second indicator circuit 12120 can include a Zenerdiode 12121, a light emitting diode 12122, and a resistor R2 12123 andthe third indicator circuit 12130 can include a Zener diode 12131, alight emitting diode 12132, and a resistor R3 12133. The Zener diodes12111, 12121, and 12131 can each have a different breakdown voltage. Forinstance, the first Zener diode 12111 can have a breakdown voltage of11.5V, for example, the second Zener diode 12121 can have a breakdownvoltage of 10V, for example, and the third Zener diode 12131 can have abreakdown voltage of 8V, for example. In such an embodiment, if thevoltage of the battery is greater than or equal to 11.5V, the LEDs12112, 12122, and 12132 will be illuminated. The illumination of all ofthe LEDs can indicate to the user of the surgical instrument that thebattery has a full charge and/or at least a sufficient charge to performany function required by the surgical instrument. If the voltage of thebattery is greater than or equal to 10V, but less than 11.5V, the LEDs12112 and 12122 will be illuminated; however, LED 12132 will not beilluminated. The illumination of LEDs 12112 and 12122, but not LED12132, can indicate to the user of the surgical instrument that thebattery has less than a full charge, but at least a sufficient charge toperform any function required by the surgical instrument. If the voltageof the battery is greater than or equal to 8V, but less than 10V, theLED 12112 will be illuminated; however, LEDs 12122 and 12132 will not beilluminated. The illumination of LED 12112, but not LEDs 12122 and12132, can indicate to the user of the surgical instrument that thebattery is nearing the end of its charge and may or may not have asufficient charge to perform certain functions required by the surgicalinstrument. Such a display of the LEDs can indicate that the battery mayneed to be replaced. If the voltage of the battery is less than 8V, noneof the LEDs 12112, 12122, and 12132 will be illuminated. Such a displayof the LEDs can indicate that the battery may not be usable to reliablyperform any function of the surgical instrument. While circuit 12100utilizes three indicator circuits 12110, 12120, and 12130, a circuit caninclude more than three indicator circuits having Zener diodes withdifferent breakdown voltages. Such an embodiment can provide a morefinely graduated indication of the voltage of the battery, for instance.Other embodiments are envisioned which utilize only two indicatorcircuits.

In various instances, a battery can include a circuit configured toindicate that the battery is charged and/or has a charge sufficientenough that it can be used with a surgical instrument. In certaininstances, a surgical instrument can include a circuit configured toindicate that a battery attached thereto is charged and/or has a chargesufficient enough that it can be used with the surgical instrument. Ineither event, turning now to FIG. 180, a circuit 12200 can include amicroprocessor 12201 which includes one or more gates in communicationwith the battery, which can be a 9V battery, for example. The circuit12200 can further comprise a capacitor 12202, such as a 10 microFaradcapacitor, for example, which can receive power from a circuit includingdiode 12203 and resistor 12204. The circuit 12200 can further comprise aLED 12205 and a resistor 12206 in the discharge path of capacitor 12202.Such a circuit can cause the LED 12205 to pulse intermittently so longas the battery can supply sufficient power to the circuit 12200. In suchinstances, a user could identify the pulsing LED 12205 and would knowthat the battery had at least some power, if not sufficient power, to beused with the surgical instrument. If the user does not identify thatthe LED 12205 is pulsing, the user can assume that the battery lackssufficient power to be used.

In various circumstances, as discussed herein and referring to FIG. 284,a battery and/or a surgical instrument configured to be used with thebattery can include a diagnostic circuit configured to evaluate thepower, voltage, and/or current that the battery can supply. Turning nowto FIG. 184, a battery diagnostic circuit 12300 is disclosed. Such acircuit can be configured to evaluate the battery before it has beenused with a surgical instrument, while it is being used with a surgicalinstrument, and/or after it has been used with a surgical instrument. Invarious instances, the battery can be used more than once and, invarious instances, the battery may be rechargeable or non-rechargeable.The uses of the battery, and the information obtained during thediagnostic evaluation of the battery, can be stored in a memory chip inthe battery and/or the surgical instrument. FIG. 183 depicts a table ofinformation 12400 which is representative of the type of informationthat could be recorded on the memory chip. For instance, the number ofuses can be recorded. For each use, the maximum voltage and/or themaximum current that the battery is charged with, or re-charged with,can be recorded, for instance. For each use, the current capacity, thecurrent used in mA, the current used in Ah, and/or the minimum voltageexperienced during use can be recorded, for instance. For each use, thetime in which the battery is charged, the time in which the battery isused, the temperature of the battery while being charged, and/or thetemperature of the battery while being used can be recorded, forinstance. These are merely a few examples of the information that can bestored. In various instances, such information can be utilized by thesurgical instrument and/or a technician to evaluate the previousperformance of the battery and/or the suitability of the battery forfurther use, for example.

In various instances, turning now to FIG. 182, a battery and/or asurgical instrument used with the battery can include a circuit forturning off the battery once the charge of the battery has fallen belowa minimum charge level. In some instances, a lithium ion battery cellmay have a thermal incident if it is used below the minimum charge leveland a shut-off circuit inhibiting the use of the battery below thisminimum charge level may inhibit such a thermal incident from occurring.

In various instances, turning now to FIG. 181, a surgical instrument caninclude a controller configured to perform a diagnostic check of theinstrument and/or the battery assembled thereto. For instance, thecontroller can include a clock and a memory chip configured to evaluateand record when the instrument and/or battery has been used. In certaininstances, the controller can be configured to disable the instrumentand/or battery if it has been too long since the last time that theinstrument and/or battery had been used. In certain instances, theinstrument and/or battery can include one or more sensors which can beconfigured to evaluate various conditions of the instrument and/orbattery, such as the temperature, the humidity, and/or the time in whichthe instrument and/or battery are exposed to the temperature and/orhumidity, for example. The controller can be configured to evaluatewhether the sensors are operating correctly and, if not, the controllercan disable the instrument and/or battery. The controller can also beconfigured to evaluate the number of times that the instrument and/orbattery have been used and, if the uses exceed a certain amount, disablethe instrument and/or battery. The controller can also be configured toevaluate the power that the battery can supply, as outlined herein, and,if the available power is insufficient, disable the instrument and/orbattery.

As described herein, a surgical instrument can include various sensorsfor gathering feedback and/or other instrument status information.Furthermore, the surgical instrument can include sensory indicators forproviding feedback and/or instrument status information to the user. Incertain instances, an endoscope can be used in connection with thesurgical instrument to provide additional feedback and/or instrumentstatus information to the user. As described herein, the endoscope andthe surgical instrument can be in signal communication with a display,which can depict the feedback from the endoscope and/or from the sensorsof the surgical instrument, for example. Referring now to FIGS. 75-93,an endoscope 5018 (FIG. 93) can be in signal communication with adisplay 5002 (FIG. 75). In certain embodiments, the display 5002 cancomprise a heads-up display (HUD) and/or a video monitor, for example.Furthermore, the display 5002 can be a plasma screen, an LCD screen, oran electroluminescent screen, for example. In various embodiments, thedisplay 5002 can broadcast a first layer of information 5010, which caninclude video feedback, for example. The video feedback can be feedbackof images viewed by an endoscope 5018 (FIG. 93) at a surgical site, forexample, and can depict at least a portion of a surgical instrument 5020as viewed by the endoscope 5018, for example.

In various embodiments, the display 5002 can include a touch screen5004. Referring primarily to FIG. 75, a user can interact with the touchscreen 5004 to interface with the display 5002 and/or the surgicalinstrument 5020. For example, the touch screen 5004 can communicate withthe display 5002, and inputs to the touch screen 5004 can adjust and/ormodify the information depicted on the display 5002. In suchembodiments, the user can communicate with the display 5002 withoututilizing an additional input to the display, such as a keyboard and/orcomputer mouse, for example. In other words, additional input toolsand/or parts may not be required to adjust and/or modify the informationdepicted on the display 5002. Furthermore, in various embodiments, thetouch screen 5004 can be easily cleaned and/or sterilized. For example,the touch screen 5004 can include a flat surface that can be easilywiped clean within a surgical suite and/or operating room. Additionallyor alternatively, the touch screen 5004 can directly and/or indirectlycommunicate with the surgical instrument 5020, such that input to thetouch screen 5004 provides input to the surgical instrument 5020. Theuser may be a surgeon, operator, and/or assistant, for example.

In various embodiments, the touch screen 5004 can be positioned over atleast a portion of the display 5002, and may be removably secured to thedisplay 5002, for example. For example, the touch screen 5004 can becompatible with multiple displays, and can be releasably attached andunattached from at least one display. Furthermore, in certainembodiments, the touch screen 5004 can be an independent display, whichcan operate independently of the display 5002. For example, a detachableLCD screen can comprise the touch screen 5004, and the detachable LCDscreen can overlay at least a portion of the display 5002. In otherembodiments, the touch screen 5004 can be integrated into the display5002. The touch screen 5004 can utilize resistive technology, capacitivetechnology, ultrasonic sound beam technology, and/or near field imagingtechnology, for example.

Referring primarily to FIG. 93, in various embodiments, a feedbackcontroller 5016 can be in signal communication with the surgicalinstrument 5020, the endoscope 5018, and/or the display 5002. In certainembodiments, a wired and/or wireless connection 5017 between thefeedback controller 5016 and the endoscope 5018 can provide videofeedback from the endoscope 5018 to the feedback controller 5016.Furthermore, a wired and/or wireless connection 5019 between thefeedback controller 5016 and the surgical instrument 5020 and/or themicrocontroller of the surgical instrument 5020 can provide the feedbackdata measured and/or detected by the surgical instrument 5020 to thefeedback controller 5016. For example, various sensors are describedherein, as well as in Zemlock '263 and Zemlock '344, the entiredisclosures of which have been incorporated herein, and the varioussensors can detect feedback and/or instrument status information.Additionally, a wired and/or wireless connection 5015 between thefeedback controller 5016 and the display 5002 can provide the feedbackdata from the surgical instrument 5020 and/or the video feedback fromthe endoscope 5018 to the display 5002. In at least one embodiment, thevideo feedback can be depicted in the first layer of information 5010 onthe display 5002, and the feedback data can be depicted in a secondlayer of information 5012 on the display 5004. In embodiments where adetachable LCD display comprising the touch screen 5004 is positionedover the display 5002, a wired and/or wireless connection between thefeedback controller 5016 and the detachable LCD display can provide thefeedback data to the detachable LCD display and/or from the LCD displayto the feedback controller 5010, for example.

Referring primarily to FIG. 76, the display 5002 can broadcast the firstlayer of information 5010, which can comprise the video feedback fromthe endoscope 5018 (FIG. 93), for example. In various instances, thevideo feedback 5010 can include a depiction of the surgical instrument5020 affecting tissue T. In various embodiments, surgical instrument5020 can be similar to surgical instrument 10 (FIG. 1), for example, andthe disposable loading unit (DLU) and/or an end effector 5022 coupled tothe surgical instrument can be similar to loading unit 20 (FIG. 2), forexample. The DLU 5022 of the surgical instrument 5020 can articulaterelative to the tissue T, grasp and/or clamp the tissue T between a pairof jaws, staple the tissue T, and/or cut the tissue T with a cuttingelement, as described herein. Furthermore, the endoscope 5018, which canbe positioned at and/or near the surgical site, can view the DLU 5022and can transmit the video feed and/or recording to the feedbackcontroller 5016 (FIG. 93). In various embodiments, the video feedback inthe first layer of information 5010 on the display 5002 can providelive, visual feedback of the surgical site to the operator of thesurgical instrument 5020.

Referring primarily to FIG. 77, the display 5002 can display a secondlayer of information 5012. Furthermore, a user can select, move, resize,minimize, expand, modify, and/or otherwise manipulate the second layerof information 5012. For example, the user can manipulate the secondlayer of information 5012 by interfacing with the touch screen 5004. Asdescribed herein, the second layer of information 5012 can includefeedback data from the surgical instrument 5020 and/or controls forcontrolling the surgical instrument 5020. In various embodiments, thesecond layer of information 5012 can include a control panel 5030, andthe touch screen 5004 can be used to select and/or utilize features ofthe control panel 5030. The control panel 5030 can be collapsible,resizable, moveable, and/or otherwise manipulatable by way of the touchscreen 5004. For example, a user can minimize or collapse the controlpanel 5030 by selecting the minimize/maximize icon 5032, and canmaximize or un-collapse the control panel 5030 by re-selecting theminimize/maximize icon 5032. Furthermore, a user can move the controlpanel 5030 on the display 5002 by “dragging and dropping” the controlpanel 5030 across the display 5002, for example. Additionally, a usercan resize the control panel 5030 relative to the display 5002 by“zooming in” and/or “zooming out” multiple contact points on the touchscreen 5004. A person having ordinary skill in the art will appreciatethat various conventional and/or intuitive contacts to the touch screen5004 can be utilized to modify and/or manipulate the second layer ofinformation 5012 and/or the control panel 5030 thereof, for example.

Referring still to FIG. 77, the control panel 5030 can include aplurality of menus, categories, and/or classifications. For example, thecontrol panel 5030 can include an instrument feedback menu 5036, adisplay menu 5060, and/or an instrument controller menu 5070. A user canutilize the control panel 5030 to select a menu and/or to switch betweenoperational states of the touch screen 5004. For example, the touchscreen 5004 can communicate directives and/or controls to the instrumentcontroller 5016 (FIG. 93) and/or the microcontroller when a user selectsthe instrument controller menu 5070 of the control panel 5030. In suchembodiments, as described herein, the touch screen 5004 may operate inan instrument-control state. Furthermore, the settings related to thesecondary layer of information 5012 and/or the display 5002, forexample, can be modified by a user when the display menu 5060 isselected from the control panel 5030. In such embodiments, the touchscreen 5004 may operate in a setting-modification state. Additionally oralternatively, the feedback data included in the secondary layer ofinformation 5012 can be modified by a user when the instrument feedbackmenu 5036 is selected. In such embodiments, the touch screen 5004 mayoperate in a feedback-manipulation state. In various embodiments, thecontrol panel 5030 can include additional and/or fewer menus,categories, and/or classifications. Furthermore, the various menus,categories, and/or classifications of the control panel 5030 can bemodified according to the user's preferences, for example. The menus,categories, and/or classifications can be verbally and/or symbolicallyindicated in the second layer of information 5012. In variousembodiments, the categories under each menu 5036, 5060, 5070 may beselectively depicted in the second layer of information 5012. Forexample, the categories under each menu 5036, 5060, 5070 may only bedepicted in the second layer of information 5012 when the respectiveoverlying menu 5036, 5060, 5070 is selected by the user. In otherembodiments, the user can manually minimize and/or maximize categoriesand/or subcategories corresponding to each menu 5036, 5060, and/or 5070,for example.

Still referring to FIG. 77, the instrument feedback menu 5036 caninclude a plurality of feedback categories, and can relate to thefeedback data measured and/or detected by the surgical instrument 5020(FIG. 93) during a surgical procedure. As described herein, the surgicalinstrument 5020 can detect and/or measure the position of a moveable jawbetween an open orientation and a closed orientation, the thickness ofclamped tissue, the clamping force on the clamped tissue, thearticulation of the DLU 5022, and/or the position, velocity, and/orforce of the firing element, for example. Furthermore, the feedbackcontroller 5016 (FIG. 93) in signal communication with the surgicalinstrument 5020 can provide the sensed feedback to the display 5002,which can display the feedback in the second layer of information 5012.As described herein, the selection, placement, and/or form of thefeedback data displayed in the second layer of information 5012 can bemodified based on the user's input to the touch screen 5004, forexample.

In various embodiments, the display menu 5060 of the control panel 5030can relate to a plurality of categories, such as unit systems 5062and/or data modes 5064, for example. In certain embodiments, a user canselect the unit systems category 5062 to switch between unit systems,such as between metric and U.S. customary units, for example.Additionally, a user can select the data mode category 5064 to switchbetween types of numerical representations (FIGS. 79-81) of the feedbackdata and/or types of graphical representations (FIGS. 82-83) of thefeedback data, for example. The numerical representations of thefeedback data can be displayed as numerical values and/or percentages,for example. Furthermore, the graphical representations of the feedbackdata can be displayed as a function of time (FIG. 82) and/or distance(FIG. 83), for example. As described herein, a user can select theinstrument controller menu 5070 from the control panel 5030 to inputdirectives for the surgical instrument 5020 (FIG. 93), which can beimplemented via the instrument controller 5016 (FIG. 93) and/or themicrocontroller, for example.

Referring now to FIG. 78, the second layer of information 5012 canoverlay at least a portion of the first layer of information 5010 on thedisplay 5002. Furthermore, the touch screen 5004 can allow a user tomanipulate the second layer of information 5012 relative to the videofeedback in the underlying first layer of information 5010 on thedisplay 5002. For example, a user can operate the touch screen 5004 toselect, manipulate, reformat, resize, and/or otherwise modify theinformation displayed in the second layer of information 5012. Incertain embodiments, the user can use the touch screen 5004 tomanipulate the second layer of information 5012 relative to the surgicalinstrument 5020 depicted in the first layer of information 5010 on thedisplay 5002. A user can select a menu, category and/or classificationof the control panel 5030 thereof, for example, and the second layer ofinformation 5012 and/or the control panel 5030 can be adjusted toreflect the user's selection. In various embodiments, a user may selecta category from the instrument feedback category 5036 that correspondsto a specific feature or features of the surgical instrument 5020depicted in the first layer of information 5010. Feedback correspondingto the user-selected category can move, locate itself, and/or “snap” toa position on the display 5002 relative to the specific feature orfeatures of the surgical instrument 5020. For example, the selectedfeedback can move to a position near and/or overlapping the specificfeature or features of the surgical instrument 5020 depicted in thefirst layer of information 5010.

Referring to FIGS. 79 and 80, if a user selects the knife progressioncategory 5040 from the instrument feedback menu 5036, for example, thesensed data and/or information related to the progression of the knifecan move and/or “snap” to a position in the second layer of information5012 relative to the knife of the DLU 5022 depicted in the first layerof information 5010, for example. Furthermore, the control panel 5030can be collapsed and/or minimized after the user selects the desiredcategory or categories from the instrument feedback menu 5036. Feedbackdata 5052 related to the progression of the knife can be depicted on thedisplay 5002 near the detected knife of the DLU 5022 depicted in thefirst layer of information 5010, and can move between a first position(FIG. 79) when the knife is near the beginning of the firing stroke anda second position (FIG. 80) when the knife is near the distal end of thefiring stroke, for example, as the knife translates and/or moves throughthe DLU 5022. For example, when the knife has translated a distance Xmm, the data 5052 related to the knife's progression can be positionedin the first position (FIG. 79), and, when the knife has translated adistance Y mm, the data 5052 related to the knife's progression can bepositioned in the second position (FIG. 80). In such embodiments, theoperator may track the progression of the knife during the firing strokeby viewing the feedback data 5052 on the screen 5002. For example, whenthe knife of the DLU 5022 is blocked from view by the end effector jaws5024 and/or tissue T, for example, the operator can track and/orapproximate the position of the knife in the DLU 5020 based on thechanging value of the feedback data 5052 and/or the shifting position ofthe feedback data 5052 relative to the DLU 5022 depicted in theunderlying first layer of information 5010. Furthermore, the display5002 can incorporate a numerical representation of the knife'sprogression, as well as a pictorial and/or symbolic representation ofthe knife's progression. For example, a symbol 5054, such as an arrow,for example, can move and/or extend relative to the DLU 5022 depicted inthe underlying first layer of information 5010 to show the progressionof the knife through the DLU 5022. Referring still to FIGS. 79 and 80,for example, the symbol 5054 can extend distally as the knife advancesdistally from a position near the beginning of the firing stroke (FIG.79) to a position near the distal end of the firing stroke (FIG. 80),for example.

In various embodiments, a user can select one or more differentcategories of feedback data from the instrument feedback menu 5036, andthe different categories of feedback data can be displayed in the secondlayer of information 5012 on the display 5002. In such embodiments, whena user selects a different category of feedback data from the instrumentfeedback menu 5036, a numerical and/or symbolic representation of thefeedback data can move to an appropriate position on the display 5002relative to the DLU 5022 depicted in the underlying first layer ofinformation 5010. For example, if a user selects the jaw positioncategory 5038 from the instrument feedback menu 5036, feedback datarelated to the position of a moveable jaw between an open position and aclamped position can be displayed in the second layer of information5012, and can move to a position near the moveable jaw(s) 5024 of thesurgical instrument 5020 on the display 5002, for example. Furthermore,if the knife speed category 5042 is selected, feedback data 5058 (FIG.82) related to the velocity of the knife can be displayed in the secondlayer of information 5012, and can move to a position near the knife inthe DLU 5022 on the display 5002, similar to the numerical data 5052and/or the symbol 5054 discussed above. If the tissue thickness category5044 is selected by a user, feedback data related to the detected tissuethickness can be displayed in the second layer of information 5012, andcan move to a position near the measured tissue T on the display 5002,for example. Furthermore, in at least one embodiment, the second layerof information 5012 can include a scale and/or a ruler, which canillustrate the detected tissue thickness. The user can move the rulervia the touch screen 5004 relative to the underlying tissue T depictedin the first layer of information 5010, which may facilitate the user'sappreciation of the tissue thickness variations, for example. If a userselects the end effector articulation category 5046, feedback data 5252(FIGS. 84-88) related to the articulation of the DLU 5022 can bedisplayed in the second layer of information 5012, and can move to aposition near the articulation joint 5026 (FIGS. 84 and 85) of the DLU5022 on the display 5002, for example. If a user selects the firingforce category 5048, the feedback data related to the firing forceexerted on the tissue by the knife can be displayed in the second layerof information 5012, and can be positioned near the knife of the DLU5022 on the display 5002, for example. Additionally, the feedback datarelated to the firing force exerted by the knife can move in the secondlayer of information 5012 as the knife moves relative to the DLU 5022,for example, during a firing stroke. Furthermore, if the clamping forcecategory 5050 is selected, feedback data 5158 (FIG. 83) related to theclamping force on the tissue T can be depicted in the second layer ofinformation 5012, and can move near the DLU 5022 depicted in theunderlying first layer of information 5010. In such embodiments, thefeedback data 5158 related to the clamping force can show variations inthe clamping pressure along the length and/or width of the DLU 5022,during clamping, and/or throughout a firing stroke, for example.

In various embodiments, the feedback depicted in the second layer ofinformation 5012 can move with the corresponding feature of the surgicalinstrument 5020 in the first layer of information 5010. For example, asthe DLU 5022 is manipulated around the surgical site, the DLU 5022 maymove around the display 5002. In such embodiments, the feedback relatedto the DLU 5022, such as the jaw position and/or the articulation data,for example, can move along with the DLU 5022. Movement of the relevantfeedback may ensure the feedback remains in the operator's field ofvision without requiring the operator to move their eyes away from thecorresponding feature of the surgical instrument 5020 depicted in thefirst layer of information 5010 on the display 5002. Furthermore, themovement of the relevant feedback may ensure the feedback does not blockthe feature(s) of the surgical instrument 5020 depicted in the firstlayer of information 5010 that the operator desires to view on thedisplay 5002.

In certain embodiments, a user can select multiple feedback categoriesto view on the display 5002 simultaneously. Furthermore, the selectedfeedback(s) can be automatically arranged on the display 5002 to displaythe relevant data in a non-overlapping arrangement in the second layerof information 5012. In other words, feedback displayed in the secondlayer of information 5012 may not overlap other feedback displayed inthe second layer of information 5012; however, such feedback may overlapthe video feedback of the first layer of information 5010 displayed onthe display 5002, for example. In various embodiments, when the feedbackdata moves and/or “snaps” to a position on the screen relative to thesurgical instrument 5020 depicted in the underlying first layer ofinformation 5010, the user can override the default position by“dragging and dropping” the feedback data elsewhere in the second layerof information 5012.

Referring now to FIG. 81, a symbolic representation 5056 of theprogression of the knife, such as a cross, bulls-eye, and/or pictorialrepresentation of the knife and/or knife edge, for example, can move toa position in the second layer of information 5012 that overlaps theposition of the knife depicted in the first layer of information 5010.In certain embodiments, even when the knife is not visible on thedisplay 5002, for example, if the view of the knife is obstructed, thesymbolic representation 5056 of the knife can move and/or follow thedetected position of the knife in the DLU 5022 on the screen 5002. Forexample, the symbolic representation 5056 can be in a first positionrelative to the DLU 5022 near the beginning of the firing stroke, andthe symbolic representation 5056 move to a second position relative tothe DLU 5022 near the end of the firing stroke.

In various embodiments, feedback selected by the user via the touchscreen 5004, can “snap” to a corner, edge and/or other predeterminedlocation on the display 5002. For example, referring still to FIG. 81,numerical data 5052 related to the knife's progression can move to acorner of the display 5002. Additionally or alternatively, a user caninterface with the touch screen 5004 to move the numerical data 5052 toa different position on the touch screen 5004. Based on the position ofthe underlying surgical instrument 5020 in the first layer ofinformation 5010, the user may move the numerical data 5052 to aposition in the second layer of information 5012 such that acorresponding and/or specific feature of the DLU 5022 is not blockedand/or obstructed by the numerical data 5052. Additionally oralternatively, the user may move the numerical data 5052 to a positionnear the corresponding feature of the DLU 5022, such that the user caneasily view the corresponding DLU 5022 feature and the numerical data5052 simultaneously.

Referring to FIGS. 84 and 85, a symbolic representation 5254 (FIG. 85)of feedback data from the feedback controller 5016 (FIG. 93) can beincluded I the second layer of information 5012. For example, a symbolicrepresentation 5254 of the articulation of the DLU 5022, such as asubtended angle and/or arc, for example can be depicted in the secondlayer of information 5012, and can move to a position on the display5002 near and/or overlapping the articulation joint 5026 of the surgicalinstrument 5020 depicted in the first layer of information 5010. Forexample, a subtended arc can extend between an axis A defined by thenon-articulated DLU 5022 (FIG. 84) and an axis A′ defined by thearticulated DLU 5022 (FIG. 85). In certain embodiments, even when thearticulation joint 5026 is not visible on the screen, the symbolicrepresentation 5254 of the articulation angle can be visible in thesecond layer of information 5012. For example, if the articulation joint5026 is not positioned within the endoscope's field of view and/or isobstructed or blocked, the symbolic representation 5254 of thearticulation angle can provide a visible indication of articulation tothe user. In various embodiments, the symbolic representation 5252 canadjust and/or change as the DLU 5022 moves and/or articulates. Forexample, the symbolic representation 5254 can be an arrowed arc or line,which can extend from the initial and/or non-articulated position of theDLU 5022 (FIG. 84) toward the articulated position of the DLU 5022 (FIG.85) as detected by the instrument 5020. Furthermore, in variousembodiments, the symbolic representation 5254 can “snap” to a positionrelative to the DLU 5022 depicted in the first layer of information,such that the symbolic representation 5254 overlaps and/or is alignedwith the DLU 5022. For example, referring primarily to FIG. 85, thesymbolic representation 5254 of the articulation angle can move atand/or near the articulation joint 5026 depicted in the first layer ofinformation 5010 on the display 5002, and can lengthen between the axisA defined by the DLU 5022 in the initial and/or non-articulated positionand the axis A′ defined by the DLU 5022 as the DLU 5022 articulates.

Furthermore, in various embodiments, numerical data 5252 related to thearticulation of the DLU 5022 can be displayed in the second layer ofinformation 5012 on the display 5002. Furthermore, the data 5252 canchange as the DLU 5022 articulates. For example, the second layer ofinformation 5012 can depict an articulation of X° before the DLU 5022articulates (FIG. 84), and can depict an articulation of Y° after theDLU 5022 articulates (FIG. 85). In various embodiments, the feedbackdata 5252 related to the articulation of the DLU 5022 can be displayedin the second layer of information 5012 at and/or near the articulationjoint 5026 of the surgical instrument 5020 depicted in the first layerof information 5010, for example. A user can utilize the touch screen5004 to move, resize, minimize, and/or otherwise manipulate thearticulation data 5252 displayed in the second layer of information 5012relative to the video feedback displayed in the first layer ofinformation 5010, for example. Additionally or alternatively, a user caninterface with the touch screen 5004 to move the symbolic representation5254 and/or the numerical data 5252 to a different position on the touchscreen 5004. Based on the position of the underlying surgical instrument5020 in the first layer of information 5010, the user may move thenumerical data 5252 to a position in the second layer of information5012 such that specific feature(s) of the DLU 5022 are not blockedand/or obstructed by the numerical data 5252. Additionally oralternatively, the user may move the numerical data 5252 to a positionnear the corresponding feature(s) of the DLU 5022, such that the usercan easily view the corresponding DLU 5022 feature(s) and the numericaldata 5252 simultaneously.

Referring now to FIG. 82, a graphical representation can be selectedfrom the display menu 5060 of the control panel 5030 by way of the touchscreen 5004, for example. In such embodiments, a graphicalrepresentation of feedback 5058 can be displayed in the second layer ofinformation 5012 on the display 5002. A user may select the graphicalrepresentation to view measured and/or sensed data from the surgicalinstrument 5020 and/or the controller thereof relative to time and/orspace. For example, a user may desire to observe the velocity of thefiring element throughout the firing stroke, and thus, may select theknife speed category 5042 (FIG. 78) from the instrument feedback menu5036 (FIG. 78). In such embodiments, the graphical representation 5058of the speed of the knife can continue to gain data points and growduring the firing stroke, for example. In various embodiments, at thecompletion of the firing stroke, the graphical representation 5058 candepict a “soft” start period 5057 and/or a “soft” stop period 5059 ofthe knife. Furthermore, the graphical representation 5058 can bepositioned on the display 5002 such that the velocity of the knife at aspecific location along the length of the end effector jaws 5024corresponds to that specific location along the length of the endeffector jaws 5022 depicted in the first layer of information 5010. Forexample, the graphical representation 5058 can begin at and/or near thebeginning of the knife's path through the DLU 5022 depicted in the firstlayer of information 5010, and can end at and/or near the end of theknife's path through the DLU 5022 depicted in the first layer ofinformation 5010, for example. Furthermore, as described herein, thegraphical representation 5058 can “snap” to an appropriate position onthe screen, and a user can utilize the touch screen 5004 to move and/orresize the graphical representation 5058 as desired. In certainembodiments, a numerical representation of the firing speed can bedepicted in the second layer of information 5012 along with thegraphical representation 5058.

Referring now to FIG. 83, in various embodiments, a user may desire toobserve the clamping force exerted on the tissue T along the lengthand/or width of the end effector jaws 5024, and thus, may select theclamping force category 5050 (FIG. 78) from the instrument feedback menu5036 (FIG. 78). In such embodiments, a graphical representation 5158 ofthe clamping force can be depicted in the second layer of information5012. In some embodiments, the graphical representation 5158 can bearranged in the second layer of information 5012 relative to the clampedtissue depicted in the first layer of information 5010. For example, thegraphical representation 5158 can begin at and/or near the proximal endof the jaws 5024 depicted in first layer of information 5010, and canend at and/or near the distal end of the jaws 5024 depicted in the firstlayer of information 5010, for example. Furthermore, as describedherein, the graphical representation 5158 can “snap” to an appropriateposition on the screen, and a user can utilize the touch screen 5004 tomove and/or resize the graphical representation 5158, for example. Incertain embodiments, the graphical representation can change during useto reflect variations in clamping pressure during a firing stroke, forexample.

Referring to FIGS. 86-88, in various embodiments, a user can interfacewith the touch screen 5004 to input controls and/or directives to thesurgical instrument 5020 via the instrument controller 5016 and/ormicrocontroller. For example, a user can input controls directed toarticulating the DLU 5022, clamping the end effector jaws 5024,advancing and/or retracting the cutting element, and/or ejecting staplesfrom the DLU 5022. In various embodiments, a user can select theinstrument controller category 5070 from the control panel 5030 via thetouch screen 5004 to activate the instrument-control state, such thatthe user can control the surgical instrument 5020 via the touch screen5004. When the touch screen 5004 is activated for instrument control, auser can interface with the touch screen 5004 to control the surgicalinstrument 5020. For example, a user can interface with control buttonsand/or icons in the second layer of information 5012 and/or caninterface with locations on the touch screen 5004 corresponding to theunderlying surgical instrument 5020 to input directives to the surgicalinstrument 5020, for example.

For example, referring to FIG. 86, a user can interface with the touchscreen 5004 to indicate the desired articulation direction and degree ofthe DLU 5022, for example. In certain embodiments, a user can drag acontact point across the touch screen 5004 from at and/or near the DLU5022 toward the desired articulated location of the end effector 5002.Referring to FIG. 86, a user can trace a line or arc 5352 from at and/ornear the DLU 5022 depicted in the first layer of information 5010 towardthe desired articulation location of the DLU 5022. For example, the arc5352 can extend from and/or approximately from the axis A defined by theDLU 5022, and the arc 5352 can extend to the axis A′ defined by thedesired articulated position of the DLU 5022. Furthermore, the arc 5352can extend in the direction indicated by the arrow 5354, for example. Incertain embodiments, an arc 5352 may not appear in the second layer ofinformation 5010 when the user inputs the desired articulation via thetouch screen 5004. In various embodiments, the touch screen 5004 cancommunicate the desired articulation angle to the instrument controller5016 (FIG. 93) and/or microcontroller, which can effect the articulationof the DLU 5022 to the desired articulation angle. Referring now to FIG.88, the instrument controller 5016 (FIG. 93) and/or microcontroller caneffect articulation of the DLU 5022 to the axis A′ based on the input ofthe user via the touch screen 5004, for example.

Referring primarily to FIG. 87, in various embodiments, a user caninterface with control buttons, schematics, and/or icons in the firstlayer of information 5012 to input directives to the surgical instrument5020. For example, the first layer of information 5012 can include asymbol or icon 5356, and the user can move and/or manipulate the icon5356 to effect articulation of the DLU 5022. In various embodiments, theicon 5356 can include a schematic of the DLU 5022, for example.Furthermore, the user can drag the icon 5356 to an articulated and/orrotated orientation to effect articulation of the DLU 5022. In variousembodiments, a line and/or arc 5358 can indicate the direction and/ordegree of articulation desired by the user. For example, the arc 5358can extend from the non-articulated orientation of the icon 5356 to thearticulated orientation of the icon 5356′. The articulated icon 5356′can correspond to the desired articulation of the DLU 5022, for example.Referring now to FIG. 88, the instrument controller 5016 and/ormicrocontroller can effect articulation of the DLU 5022 to the axis A′based on the input of the user via the touch screen 5004, for example.For example, the DLU 5022 can be articulated to the subtended angledefined by the arc 5358 between the non-articulated icon 5356 and thearticulated icon 5356′ shown in FIG. 87.

Referring primarily to FIGS. 89 and 90, in various embodiments, a usercan interface with the touch screen 5004 to input directives to thesurgical instrument 5020 related to the closure of the jaws 5024. Incertain embodiments, a user can drag a contact point across the touchscreen 5004 from at and/or near the moveable jaw 5024 toward the closedorientation of the moveable jaw 5024 to initiate closure of the jaw5024. For example, a user can trace a line or arc 5362 (FIG. 89) from atand/or near the moveable jaw 5024 depicted in the first layer ofinformation 5010 toward the desired closed orientation of the moveablejaw 5024. In various embodiments, the touch screen 5004 can communicatethe closure motion to the instrument controller 5016 and/ormicrocontroller, which can affect the closure of the moveable jaw(s)5024. In certain embodiments, the arc 5362 traced by the user on thetouch screen 5004 can extend from and/or approximately from the axis Adefined by the moveable jaw 5024, and the arc 5362 can extend to theaxis A′ (FIG. 90) defined by the desired clamped orientation of themoveable jaw 5024. Furthermore, the arc 5362 can extend in the directionindicated by the arrow 5364, for example. Referring now to FIG. 90, theinstrument controller 5016 and/or microcontroller can affect closure ofthe moveable jaw 5024 to the axis A′ based on the input of the user viathe touch screen 5004, for example.

Referring now to FIGS. 91 and 92, in various embodiments, a user caninterface with control buttons and/or icons in the first layer ofinformation 5012 to input directives to the surgical instrument 5020.For example, the first layer of information 5012 can include a controlinterface 5072, which can include buttons 5074, 5075, 5076, 5077, 5078for inputting directives to the instrument controller 5016 and/ormicrocontroller, for example. Buttons for inputting directives to theinstrument controller 5016 (FIG. 93) and/or microcontroller can relateto articulating the DLU 5022, closing and/or clamping the jaws 5024,firing and/or retracting the cutting element, and/or ejecting staplesfrom the DLU 5022, for example. The user can interface with the touchscreen 5004 to select a button or buttons from the control interface5072. Referring primarily to FIG. 91, the control interface 5072 caninclude a stop/retract button 5474, a pause button 5475, a start button5476, a speed-up button 5477, and/or a speed-down button 5478, forexample. The user can contact the start button 5476 to initiate thefiring stroke and/or advance the firing element, the pause button 5475to pause the firing stroke, and/or the stop/retract button 5474 to stopthe firing stroke and retract the firing element, for example.Furthermore, the user can interface with the control interface 5072 toadjust the speed of the firing element throughout the firing stroke. Forexample, the user can contact the speed-up button 5477 to increase thevelocity of the firing element, and the user can contact the speed-downbutton 5478 to decrease the velocity of the firing element. A user mayincrease the velocity of the firing element after and/or during a “soft”start phase of the firing stroke, for example, and/or may decrease thevelocity of the firing element for a “soft” stop phase of the firingstroke toward an end of the firing stroke, for example. In otherembodiments, the control interface 5072 can include buttons and/orcontrols for modifying the closure of the jaws 5024, and/or thearticulation of the DLU 5022, for example. In various embodiments, thecontrol interface 5072 can “snap” to a position in the second layer ofinformation 5012 when the instrument controller 5070 menu is selectedfrom the control panel 5030 and/or when the instrument-control state isotherwise selected by the user. The user can move, adjust and/ormanipulate the control interface 5072 relative to the first layer ofinformation 5010 and/or the display 5002, for example.

In various embodiments, referring to FIG. 92, the secondary layer ofinformation 5012 can include a progression bar 5480, which can indicatethe position of the firing element in the DLU 5022, for example. Theprogression bar 5480 can extend between a proximal end 5482 and a distalend 5488, and can define a proximal-most position and a distal-mostposition of the firing element during a firing stroke. In variousembodiments, the position of the firing element can be indicated alongthe progression bar 5480, for example. In certain embodiments, the usercan use the controls in the control interface 5072 to adjust the firingstroke. For example, the user can interface with the control interface5072 to initiate and/or terminate the “soft” start and/or “soft” stopphases of the firing stroke based on the indicated position of thefiring element along the progression bar 5480. Furthermore, theprogression bar 5480 can include measurement indicia and/or guides 5484,5486, which can be set to positions along the progression bar 5480 where“soft” start and/or “soft” stop phases may begin and/or end, forexample. The guides 5484, 5486 can provide a visual suggestion to theuser to initiate and/or terminate the “soft” start period with thespeed-up button 5077 and/or the “soft” stop phase with the speed-downbutton 5078 during the firing stroke, for example. In variousembodiments, the position of the guides 5484, 5486 can be preset by theuser.

Referring still to FIG. 92, in various embodiments, the instrumentcontroller 5016 and/or microcontroller can automatically affectvariations in the speed of the firing element based on the position ofthe guides 5484, 5486 along the progression bar 5480. Furthermore, theuser can interface with the touch screen 5004 to move and/or manipulatethe progression bar 5480, and thus, to modify the “soft” start and“soft” stop phases of the firing stroke. For example, the “soft” startand/or “soft” stop phases can be set at predetermined positions alongthe progression bar 5480 between the proximal end 5482 and the distalend 5488. In certain embodiments, the user can interface with the touchscreen 5004 to move and/or adjust the position of the guides 5484, 5486along the length of the progression bar 5480. For example, the user cantoggle the guides 5484, 5486 between a plurality of positions on theprogression bar 5480 by dragging and releasing the guides 5484, 5486 tolengthen and/or shorten the “soft” start and/or “soft” stop phases ofthe firing stroke. In certain embodiments, the user can interface withthe touch screen 5004 to move and/or adjust the position of the distalend 5488 of the progression bar 5480 to lengthen and/or shorten a firingstroke. For example, the user can drag the distal end 5488 proximally toshorten the firing stroke. and/or can drag the distal end 5488 distallyto lengthen the firing stroke, for example. In various embodiments, theinstrument controller 5016 and/or microcontroller can adjust the speedof the firing element and/or firing stroke length based on the modifiedpositions of the guides 5484, 5486 and/or the distal end 5488 along theprogression bar 5480, for example.

In various embodiments, the surgical instrument 10 can include at leastone deactivation mechanism. As described in greater detail herein, sucha deactivation mechanism can discourage an end user from tampering withthe surgical instrument. For example, referring now to FIG. 134, a powersource 2500 is illustrated. The power source 2500 can be used to supplypower to a surgical instrument such as, for example, the surgicalinstrument 10 (See FIG. 1) and is similar in many respects to otherpower sources described elsewhere in this document such as, for example,the power source 200 (See FIG. 1), and other power sources of the typedescribed in further detail Zemlok '763, which has been hereinincorporated by reference in its entirety. To protect the power source2500 from tampering, the power source 2500 can be configured to becomeinoperable or inactive in the event it is tampered with. For example,the power source 2500 can become inactive by ceasing to receive, store,and/or transmit energy, for example. Protection from tampering mayensure proper operation of the power source 2500 during use with thesurgical instrument 10.

Referring to FIGS. 134 and 135, the power source 2500 may include anouter casing 2502 which may enclose various components of the powersource 2500 such as, for example, a battery pack 2510. The casing 2502may include a first shell 2504 and a second shell 2506 which can beseparably coupled to the first shell 2504, as illustrated in FIG. 135.In certain examples, the shells 2504 and 2506 can be formed from athermoplastic material such as, for example, polycarbonate. Alternately,other materials having appropriate characteristics may be used.Furthermore, the shells 2504 and 2506 can be coupled to each other byone or more fastening techniques such as, for example, adhesives,welding, interlocking structures, and/or screws. In one example, theshells 2504 and 2506 can be secured together via a snap fit typeengagement. In another example, the shells 2504 and 2506 can be securedtogether by fastening members 2508, as illustrated in FIG. 135.

Referring to FIGS. 135-137, the power source 2500 may include adeactivation mechanism 2512 which may render the power source 2500inoperable if the power source 2500 is compromised. For example, thedeactivation mechanism 2512 may render the power source 2500 inoperableif the casing 2502 is tampered with. As illustrated in FIGS. 135-137,the deactivation mechanism 2512 may comprise a circuit 2514 which mayinclude a breakable portion 2516 (See FIG. 136). In certain examples,the breakable portion 2516 may be comprised of a conductive materialthat can be easily ruptured. As illustrated in FIG. 136, the circuit2514 may be coupled to the battery pack 2510 and may allow current toflow for as long as the breakable portion 2516 remains intact. Breakingthe breakable portion 2516, as illustrated in FIG. 137, may interruptthe circuit 2514 thereby terminating the flow of current through it.Further to the above, as illustrated in FIG. 135, the circuit 2514 canbe positioned such that the breakable portion 2516 may be ruptured whenthe first shell 2504 and the second shell 2506 are separated from eachother which may render the power source 2500 unable to receive, store,and/or supply power to the surgical instrument 10 without a significanteffort to repair the ruptured circuit 2514.

Referring to FIG. 135, the power source 2500 may comprise one or morebattery cells depending on the current load needs of the instrument 10.In various aspects, the power source 2500 may include a battery packsuch as, for example, the battery pack 2510 which may include aplurality of battery cells which may be connected in series with eachother. The power source 2500 can be replaceable. In certain aspects, thepower source 2500 may comprise a rechargeable battery (e.g., lead-based,nickel-based, lithium-ion based, etc.). The battery cells may be, forexample, 3-volt lithium battery cells, such as CR 123A battery cells,although in other embodiments, different types of battery cells could beused (including battery cells with different voltage levels and/ordifferent chemistries). A user may disconnect and remove a depletedpower source 2500 from the surgical instrument 10 and connect a chargedpower source 2500 in its place. The depleted power source 2500 can thenbe charged and reused. It is also envisioned that the power source 2500may include at least one disposable battery. In various aspects, thedisposable battery may be between about 9 volts and about 30 volts. Auser may disconnect and remove a depleted disposable power source 2500and connect a new disposable power source 2500 to power the surgicalinstrument 10.

As described above, the power source 2500 may include rechargeablebattery cells and can be removably placed within the handle portion 14of the housing 12, for example (see FIG. 1). In such circumstances, thepower source 2500 can be charged using a charger base which may comprisea power source for charging the power source 2500. A deactivationmechanism such as, for example, the deactivation mechanism 2512 can beutilized to prevent the power source 2500 from being recharged by thecharger base if the power source 2500 is tampered with as describedabove. For example, the circuit 2514 may be coupled to the battery pack2510 and may be couplable to the charger base to permit the charger baseto recharge the battery pack 2510. As described above, the breakableportion 2516 (See FIG. 135) may be broken when the first shell 2504 isseparated from the second shell 2506 thereby interrupting current flowthrough the circuit 2514 which may prevent the charger base fromrecharging the battery pack 2510. This may be advantageous indiscouraging an end user from tampering with the power source 2500because tampering with the power source 2500 may render it incapable ofbeing recharged for subsequent use with the surgical instrument 10.

Referring now to FIGS. 138-141, the power source 2500 may include a datastorage unit such as, for example, memory 2552 which may store dataincluding information about the power source 2500 such as, for example,total charge available, number of uses, and/or performance.Additionally, the memory 2552 may store data about the surgicalinstrument 10 including a variety of information about the operation ofthe surgical instrument 10 during a surgical procedure such as, forexample, various sensor readings, number of firings, number ofcartridges utilized, and/or information about treated patients. Thememory 2552 may include any means for storing software, including butnot limited to ROM (read only memory), RAM (random access memory), PROM(programmable ROM), EEPROM (electrically erasable PROM), and/or othercomputer-readable media.

Further to the above, referring again to FIGS. 138-141, the power source2500 may include a data access portal such as, for example, I/Ointerface 2550 to provide access to data stored in the memory 2552. Forexample, the I/O interface 2550 may allow data stored in the memory 2552of the power source 2500 to be downloaded to an external computer devicefor evaluation and analysis. In certain circumstances, the I/O interface2550 may be a wired interface and may be operably coupled to adeactivation mechanism 2512 which may include a rupturable connectionthat can be severed to prevent data transmission through the I/Ointerface 2550. Similar to the breakable portion 2516 of thedeactivation mechanism 2512, the rupturable connection of thedeactivation mechanism 2554 can be positioned such that it may besevered when the casing 2502 is breached such as, for example, when thefirst shell 2504 and the second shell 2506 are separated from eachother.

Further to the above, as illustrated in FIGS. 139-141, the I/O interface2550 may include a connector 2555 which may be configured to receive acorresponding connector 2556 from the external computer device, forexample, to permit data transfer between the memory 2552 and thecomputer device. In addition, the connector 2554 can be protected by acover such as, for example, pivoting cover 2559 which may be configuredto move between a locked position (See FIG. 139), wherein the connector2554 is unexposed and an unlocked position (See FIG. 140), wherein theconnector 2554 is exposed to receive the corresponding connector 2556.In one example, a helical screw 2558 may be used to secure the pivotingcover 2559 to the casing 2502. Other means for reversibly covering theconnector 2556 is contemplated by the present disclosure. Further to theabove, in certain examples, the connectors 2554 and 2556 may include akey and lock type engagement wherein the connectors 2554 and 2556 maycomprise, for example, unique complimenting geometries that prevent theconnector 2554 from receiving other connectors in order to prevent or atleast limit unauthorized access to data stored within the memory 2552.In certain examples, the connector 2554 can be positioned within thecasing 2502, as illustrated in FIG. 141, to further limit unauthorizedaccess to the data stored in the memory 2552. In such circumstances, theconnector 2554 can be accessed by separating the first shell 2504 fromthe second shell 2506 of the casing 2502. However, as described above ingreater detail, the deactivation mechanism 2512 may render the powersource 2500 inoperable upon breach of the casing 2502 which may furtherdiscourage from attempting to expose the connector 2554 to gain accessto the data stored in the memory 2552.

Referring to FIG. 142, the power source 2500 may include a processor2560 which may manage the data stored in the memory 2552. To protectsuch data from unauthorized access, the processor 2560 may be coupled toa breach sensing mechanism 2562. For example, the processor 2560 maycoupled to the circuit 2514 and may be configured to detect rupture ofthe breakable portion 2516. In one example, the breach sensing mechanism2562 may include one or more sensors configured to detect a breach inthe casing 2502. In any event, upon detecting a breach, the processor2560 can be programmed to prevent unauthorized access to the data storedin the memory 2552, for example, by deleting or encrypting the data.

Referring to FIGS. 143-145, a surgical instrument 2600 is depicted. Thesurgical instrument 2600 is similar to the surgical instrument 10 (SeeFIG. 1) and/or the surgical instrument 2100 (See FIG. 146) in manyrespects. For example, the surgical instrument 2600 may include ahousing assembly 2602 which is similar to the housing assembly 2102 ofthe surgical instrument 2100 and/or the housing 12 of the surgicalinstrument 10. Furthermore, the surgical instrument 2600 may include apower source 2500′ which can be used to supply power to the surgicalinstrument 2600 and is similar in many respects to other power sourcesdescribed elsewhere in this document such as, for example, the powersource 2500 (See FIG. 134), and other power sources of the typedescribed in further detail in Zemlok '763, which has been hereinincorporated by reference in its entirety. In addition, as illustratedin FIG. 143, the power source 2500′ may include a charge level indicator2660 which can be configured to provide feedback to a user about thecharge level of the power source 2500′. The feedback can be in the formof sound and/or light, for example. The power source 2500′ may includeone or more light emitting diodes (LED). The processor 2560, forexample, can be programmed to control the LEDs to provide feedback to auser about the charge level of the power source 2500′ as can be measuredby a charge meter, for example.

As illustrated in FIGS. 143-145, the power source 2500′ may include afirst LED 2662 and a second LED 2664. The processor 2560 can be coupledto the LEDs 2662 and 2664 and may be programmed to illuminate both ofthe LEDs 2662 and 2664 upon receiving a signal from the charge meterthat the power source is fully charged. In addition, the processor 2560may be programmed turn off both of the LEDS 2662 and 2664 upon receivinga signal from the charge meter that the power source is empty.Furthermore, the processor 2560 may be programmed to illuminate only thefirst LED 2662 but not the second LED 2664 upon receiving a signal fromthe charge meter that the power source includes sufficient charge foronly one complete operation of the surgical instrument 2600. Other meansfor alerting a user as to the charge level of the power source 2500′ arecontemplated by the present disclosure.

In certain embodiments, various components of the surgical instrument 10can be reusable and various components can be replaceable, for example.Furthermore, the surgical instrument 10 can be at least partiallyassembled, disassembled, and/or reassembled. For example, the surgicalinstrument 10 can be at least partially disassembled and reassembledwith reusable components and replacement components, for example.Additionally, the surgical instrument 10 can be at least partiallydisassembled for cleaning, disinfecting, and/or reprocessing betweensurgical procedures. Subsequently, the surgical instrument 10 can bereassembled, for example. As described in greater detail herein, variousfeatures, assemblies and/or systems of the surgical instrument 10 canfacilitate disassembly and assembly thereof. For example, referring nowto FIGS. 146-148, a surgical instrument 2100 is depicted. The surgicalinstrument 2100 is similar to the surgical instrument 10 (See FIG. 1) inmany respects. For example, the surgical instrument 2100 may include ahousing assembly 2102 which is similar to the housing 12 of the surgicalinstrument 10. In addition, the housing assembly 2102 may includeseveral detachable components 2103 which can be detachably secured to ahousing body 2104 such as, for example, a working assembly 2106. Othercomponents of the housing assembly 2102 can be detachably secured to thehousing body 2104. For example, the housing assembly 2102 may include areplaceable power source 2108 which can be detachably secured to ahandle portion 2110 of the housing body 2104. The power source 2108 issimilar in many respects to other power sources described elsewhere inthis document such as, for example, the power source 200 (See FIG. 1).

Referring again to FIG. 147, the housing assembly 2102, or some or allof its components can be reusable. In other words, the housing assembly2102, or some or all of its components can be utilized in multiplesurgical procedures which may require for the housing assembly 2102 tobe cleaned, disinfected, and/or reprocessed between surgical procedures.The ability to reversibly disassemble the housing assembly 2102, orremove some or all of its components such as, for example, the workingassembly 2106 in a simple and reproducible manner may simplify the stepsof cleaning, disinfecting, and/or reprocessing of the housing assembly2012 and/or may reduce cost.

Referring to FIG. 147, the housing assembly 2102 may be disassembledfollowing a surgical procedure and the components of the disassembledhousing assembly 2102 such as, for example, the housing body 2104, theworking assembly 2106 and/or the power source 2110 can be cleaned,disinfected, and/or reprocessed each separately or in combination withother components depending on the characteristics and internal parts ofeach component. In certain examples, the housing body 2104 can bedisposable. Said another way, the housing assembly 2102 may bedisassembled following a surgical procedure and the housing body 2104can be replaced with a new housing body 2104. The remaining components,however, can be cleaned, disinfected, and/or reprocessed then attachedto the new housing body 2104. The reader will appreciate that othercomponents of the housing assembly 2102 can also be disposable and canbe replaced with new like components.

Referring again to FIGS. 146-148, the housing body 2104 can beconfigured to permit assembly and disassembly of the housing assembly2102 in a simple, predictable, and reproducible manner. For example, thehousing body 2104 can include a first shroud portion 2112 (See FIG. 147)and a second shroud portion 2114 (See FIG. 146) which can be releasablyattached to the first shroud portion 2112. In one example, the shroudportions 2112 and 2114 can include a snap fit type engagement. Theshroud portions 2112 and 2114 can be adapted for matting engagement witheach other. In one example, the shroud portion 2112 can include aplurality of female members 2116 (See FIG. 147) which may be cylindricalin shape and configured to receive corresponding male members (notshown) disposed on the shroud portion 2114 in a snap fit engagement whenthe shroud portions 2112 and 2114 are assembled together.

Further to the above, the working assembly 2106 can be nested in thefirst shroud portion 2112. As illustrated in FIG. 147, the second shroudportion 2114 can be removed to expose the working assembly 2106 nestedin the first shroud portion 2112 in order to permit a user to remove theworking assembly 2106 from the housing body 2104. The working assembly2106, as illustrated in FIG. 147, may include a motor 2118 which maygenerate rotational motions to effectuate an end effector (e.g., thecartridge/anvil portion of the loading unit 20 illustrated in FIG. 2).The motor 2118 is similar in many respects to other motors describedelsewhere in this document such as, for example, the motor 100 (See FIG.1). In addition, the working assembly 2106 may also include atransmission assembly 2120 which can be operably coupled to the motor2118 and is similar in many respects to other transmission assembliesdescribed elsewhere in this document such as, for example, the gearassembly 170 (See FIG. 5). Furthermore, the working assembly 2106 mayalso include a firing member assembly 2122 which may transform therotational motions generated by the motor 2118 into axial motions whichcan be transmitted to the end effector through a firing rod 2124. Thefiring member assembly 2122 is similar in many respects to other driveassemblies described elsewhere in this document such as, for example,the firing member assembly 82.

Referring to FIGS. 147 and 148, the first shroud portion 2112 mayinclude a plurality of compartments designed and spaced to receive theworking assembly 2106. For example, the shroud portion 2112, asillustrated in FIG. 147, may include a motor nesting compartment 2126which can be spaced to accommodate the motor 2118. In certain examples,the motor nesting compartment 2126 can be designed to fit the motor 2118in a specific arrangement to ensure accurate assembly. In addition, themotor nesting compartment 2126 may include assembly instructions whichcan be, for example, molded onto a wall of the motor nesting compartment2126 to ensure correct assembly. For instance, the side walls of themotor nesting compartment 2126 can be configured to closely receive themotor 2118. Moreover, the sideways can be asymmetrically configured, atleast in some respects, to receive the motor 2118 in only oneorientation, i.e. the correct orientation.

Similarly, the shroud portion 2112, as illustrated in FIG. 147, mayinclude a transmission assembly nesting compartment 2128 which can bespaced to accommodate the transmission assembly 2120. Furthermore, incertain examples, the transmission assembly nesting compartment 2128 canbe designed to fit the transmission assembly 2120 in a specificarrangement to ensure accurate assembly. For instance, the side walls ofthe transmission assembly nesting compartment 2128 can be configured toclosely receive the transmission assembly 2120. Moreover, the sidewayscan be asymmetrically configured, at least in some respects, to receivethe transmission assembly 2120 in only one orientation, i.e. the correctorientation. In addition, the transmission assembly nesting compartment2128 may include assembly instructions which can be, for example, moldedonto a wall of the transmission assembly nesting compartment 2128 toensure correct assembly. Similarly, the shroud portion 2112, asillustrated in FIG. 147, may include a firing member assembly nestingcompartment 2130 which can be spaced to accommodate the firing memberassembly 2122. Furthermore, in certain examples, the firing memberassembly nesting compartment 2130 can be designed to fit the firingmember assembly 2122 in a specific arrangement to ensure accurateassembly. For instance, the side walls of the firing member assemblynesting compartment 2130 can be configured to closely receive the firingmember assembly 2122. Moreover, the sideways can be asymmetricallyconfigured, at least in some respects, to receive the firing memberassembly 2122 in only one orientation, i.e. the correct orientation. Inaddition, the firing member assembly nesting compartment 2130 mayinclude assembly instructions which can be, for example, molded onto awall of the firing member assembly nesting compartment 2130 to ensurecorrect assembly. The reader will appreciate that other components ofthe working assembly 2106 may also be provided with unique designatedaccommodating compartments within the shroud portion 2112. The readerwill also appreciate that electrical contacts for the components of theworking assembly 2106 can also be embedded with the compartments of theshroud portion 2112 such that upon correct assembly, electricalconnections can be established between the working assembly 2106, othercomponents of the housing assembly 2102 such as, for example, the powersource 2108, and/or other components of the surgical instrument 2100.

Further to the above, the working assembly 2106 can be separably coupledto the firing rod 2124, as illustrated in FIG. 147, which may permit auser to remove and reconnect the working assembly 2106 as a single unitto the surgical instrument 2100 to simplify disassembly and reassemblyof the working assembly 2106. In one example, as illustrated in FIG.147, the firing member assembly 2122 may include a hollow tubular distalportion 2132 which may include a distal opening configured to receiveand releasably lock onto a proximal portion 2134 of the firing rod 2124in a snap fit type engagement, for example.

Referring again to FIGS. 147 and 148, other components of the housingassembly 2102 can be nested in dedicated compartments in the shroudportion 2112 in a similar manner to the working assembly 2106. Forexample, the shroud portion 2112 may include a power source nestingcompartment 2136 which can be spaced to accommodate the power source2108. Furthermore, in certain examples, the power source nestingcompartment 2136 can be designed to fit the power source 2108 in aspecific arrangement to ensure accurate assembly. For instance, the sidewalls of power source nesting compartment 2136 can be configured toclosely receive the power source 2108. Moreover, the sideways can beasymmetrically configured, at least in some respects, to receive powersource 2108 in only one orientation, i.e. the correct orientation. Inaddition, the power source nesting compartment 2136 may include assemblyinstructions which can be, for example, molded onto a wall of the powersource nesting compartment 2136 to ensure correct assembly.

Further to the above, as illustrated in FIGS. 147 and 148, certain userinput mechanisms such as, for example, firing button 2138 and/or closureswitch 2140 can also be detachable from the housing body 2104 which mayinclude a firing button nesting compartment 2142 spaced to accommodatethe firing button 2138 and/or a closure switch nesting compartment 2144spaced to accommodate the closure switch 2140. Furthermore, in certainexamples, the firing button nesting compartment 2142 can be designed tofit the firing button 2138 in a specific arrangement to ensure accurateassembly. For instance, the side walls of firing button nestingcompartment 2142 can be configured to closely receive the firing button2138. Moreover, the sideways can be asymmetrically configured, at leastin some respects, to receive the firing button 2138 in only oneorientation, i.e. the correct orientation. Similarly, the closure switchnesting compartment 2144 can be designed to fit the closure switch 2140in a specific arrangement to ensure accurate assembly. For instance, theside walls of closure switch nesting compartment 2144 can be configuredto closely receive the closure switch 2140. Moreover, the sideways canbe asymmetrically configured, at least in some respects, to receive theclosure switch 2140 in only one orientation, i.e. the correctorientation. In addition, the firing button nesting compartment 2142and/or the closure switch nesting compartment 2144 may include assemblyinstructions which can be, for example, molded onto a wall of the firingbutton nesting compartment 2142 and/or the closure switch nestingcompartment 2144 to ensure correct assembly.

Referring again to FIGS. 147 and 148, in addition to the nestingcompartments, the shroud portion 2112 can include securing mechanism(s)to secure some or all of the detachable components 2103 of the housingassembly 2102 in their respective compartments to ensure that thedetachable components 2103 remain nested in their respectivecompartments. Such securing mechanisms may include securing memberswhich can be movable between an unlocked configuration (See FIG. 148)and a locked configuration (See FIG. 147) to lock the detachablecomponents 2103 of the housing assembly 2102 to their respectivecompartments in the shroud portion 2112. The reader will appreciate thata single or multiple securing members can be utilized to secure one ormore of the detachable components 2103 to the shroud portion 2112. Inaddition, the securing mechanisms may also include safety features thatmay prevent the securing members from moving to the locked configurationin event of incorrect assembly to ensure correct assembly of thedetachable components 2103 of the housing assembly 2102. As illustratedin the exemplary embodiment in FIG. 147, the working assembly 2106 canbe secured to the shroud portion 2112 by several of the securing memberssuch as, for example, a motor securing member 2148, a transmissionassembly securing member 2150, and/or a firing member assembly securingmember 2152. In certain examples, as illustrated in FIG. 147, a powersource securing member 2154, a firing button securing member 2156, and aclosure switch securing member 2158 can be utilized to secure the powersource 2108, the firing button 2138, and the closure switch 2140,respectively.

The securing members may clamp onto the detachable components 2103 bymoving from the unlocked configuration (See FIG. 148) to the lockedconfiguration (See FIG. 147). For example, the motor securing member2148 may clamp onto the motor 2118 by moving from the unlockedconfiguration (See FIG. 148) to the locked configuration (See FIG. 147).In certain examples, some or all of the detachable components 2103 maycomprise tracks configured to receive the securing members as they movefrom the unlocked configuration to the locked configuration. The trackscan be positioned such that they may be aligned to receive the movingsecuring members only when the detachable components 2103 are correctlynested within their respective compartments in the shroud portion 2112.For example, if the motor 2118 is not correctly nested in the motornesting compartment 2126, the motor securing member 2148 may not becorrectly aligned with its track and as such upon moving the motorsecuring member 2148 from the unlocked configuration to the lockedconfiguration, the motor securing member 2148 may not enter the trackand, for example, may abut against an outer wall of the motor 2118. Incertain examples, the motor securing member 2148 can be positioned suchthat it may prevent the first shroud portion 2112 from mating engagementwith the second shroud portion 2114 if a user attempts to assemble theshroud portions 2112 and 2114 while the motor securing member 2148 isnot in the locked configuration. This arrangement may alert a user torecheck the assembled components of the housing assembly 2102 forcorrect assembly.

Similar to the motor securing member 2148, the transmission assemblysecuring member 2150 may be received in a dedicated track on thetransmission assembly 2120 and the transmission assembly securing member2150 can be positioned such that it aligns with its respective trackonly if the transmission assembly 2120 is correctly nested in thetransmission assembly nesting compartment 2128. In addition, the firingmember assembly securing member 2152 may be received in a dedicatedtrack on the firing member assembly 2122, for example, and the firingmember assembly securing member 2152 can be positioned such that italigns with its track only if the firing member assembly 2122 iscorrectly nested in the firing member assembly nesting compartment 2130.Also similar to the motor securing member 2148, the transmissionassembly securing member 2150 and/or the firing member assembly securingmember 2152 can be positioned such that either may prevent the firstshroud portion 2112 from mating engagement with the second shroudportion 2114 if a user attempts to assemble the shroud portions 2112 and2114 while the transmission assembly securing member 2150 and/or thefiring member assembly securing member 2152 are not in the lockedconfiguration. As described above, some of the detachable components2103 can be detached and reattached to the shroud member 2112 togetheras an assembly and can be secured by a plurality of the securingmembers. For example, the working assembly 2106 can be secured to theshroud portion 2112 by the motor securing member 2148, the transmissionassembly securing member 2150 and/or the firing member assembly securingmember 2152, as illustrated in FIG. 147. Such arrangement may provide anadditional level of insurance of correct assembly as failure tocorrectly assemble any one of the components of the working assembly2106 may prevent its corresponding securing member from reaching thelocked configuration which may prevent the first shroud portion 2112from mating engagement with the second shroud portion 2114 if a userattempts to assemble the shroud portions 2112 and 2114 while at leastone of the securing members remains short of the locked configuration.

Referring again to FIGS. 147 and 148, some or all of the securingmembers can be pivotally attached to the first shroud portion 2112 andcan be movable relative to the first shroud portion 2112 from theunlocked configuration (See FIG. 148) to the locked configuration (SeeFIG. 147), and vice versa. In certain examples, the second shroudportion 2114 can include protruding securing members (not shown)configured to be received within corresponding receiving member (notshown) in the detachable components 2103 nested in the first shroudportion 2112 when the shroud portions 2112 and 2114 are aligned formating engagement during assembly of the housing assembly 2102. Theprotruding securing members may ensure that the detachable components2103 remain secured in the first shroud portion 2112. In addition, theprotruding securing members may prevent the first shroud portion 2112from mating engagement with the second shroud portion 2114 if a userattempts to assemble the shroud portions 2112 and 2114 while theprotruding securing members are not be properly aligned with theircorresponding receiving members, for example due to incorrect assemblyof the detachable components 2103, which may alert the user to recheckthe assembly of the detachable components 2103 of the housing assembly2102 for correct assembly. The reader will appreciate that the positionsof the protruding securing members and their respective receivingmembers can be reversed such that the protruding securing members can beconfigured to protrude from the detachable components 2103 and bereceived in corresponding receiving member on the second shroud portion2114. In any event, the protruding securing members and theircorresponding receiving members can be releasably attachable to oneanother in a snap fit type engagement, for example. Other engagementmechanisms are contemplated by the present disclosure.

Further to the above, some or all of the detachable components 2103 mayinclude camming surfaces configured to receive the securing members ofthe first shroud portion 2112 as they are moved from the unlockedconfiguration (See FIG. 148) to the locked configuration (See FIG. 147).The camming surfaces can be disposed on an outer surface of some or allof the detachable components 2103 and may allow corresponding securingmembers to apply pressure onto the detachable components 2103 in thelocked configuration. For example, the motor 2118 may include a cammingsurface along its track. As the motor securing member 2148 is moved fromthe unlocked configuration (See FIG. 148) to the locked configuration(See FIG. 147), the motor securing member 2148 may travel along thecamming surface on the motor 2118 which may allow the motor securingmember 2148 to apply an increasing pressure onto the motor 2118 with amaximum pressure, for example, at the locked configuration. The pressureapplied onto the motor 2118 may assist in securing the motor in themotor nesting compartment 2126.

As discussed above, an end effector can include a firing member whichcan be advanced distally to staple and/or incise tissue. Referring nowto FIG. 155, an end effector 11260 can comprise a first jaw including ananvil 11262 and a second jaw including a staple cartridge 11264. The endeffector 11260 can further comprise, one, a housing and/or frame 11261extending proximally from the anvil 11262 and the staple cartridge 11264and, two, a firing member 11266 which can be moved relative to thehousing 11261, the anvil 11262, and the cartridge 11264. The endeffector 11260 can further comprise an articulation joint 11230configured to permit the anvil 11262 and the cartridge 11264 to bearticulated by an articulation driver 11268. In use, the end effector11260 can be assembled to a shaft 11240 of a surgical instrument, forexample, such that, one, the end effector housing 11261 is coupled to ashaft housing 11241 configured to support the end effector housing11261, two, the end effector firing member 11266 is coupled to a shaftfiring actuator 11246 configured to advance and retract the end effectorfiring member 11266 and/or, three, the end effector articulation driver11268 is coupled to a shaft articulation actuator 11248 configured toadvance and retract the end effector articulation driver 11268. In use,the firing member 11266 can be advanced distally to move the anvil 11262from an open position in which tissue can be positioned intermediate theanvil 11262 and the cartridge 11264 to a closed position in which theanvil 11262 compresses the tissue against the cartridge 11264. Invarious circumstances, the firing member 11266 can include a firstengagement member configured to engage the first jaw and a secondengagement member configured to engage the second jaw when the firingmember 11266 is advanced distally such that the anvil 11262 can bepivoted toward the staple cartridge 11264 by the engagement members. Inorder to re-open the end effector and allow the anvil 11262 to bereturned to its open position, the firing member 11266 must besufficiently retracted. In various circumstances, the firing member11266 may become stuck in an at least partially fired position and, as aresult, the anvil 11262 may not be reopened thereby making the removalof the surgical instrument from the surgical site difficult.

Turning now to FIGS. 156-161, an end effector, such as end effector11360, for example, can include a firing member which can permit theanvil 11262 of the end effector 11360 to be re-opened eventhough thefiring member of the end effector 11360 is stuck in an at leastpartially fired position. More particularly, the end effector 11360 caninclude a firing member 11366 comprising separable portions 11366 a and11366 b which can be configured to permit relative movement between theanvil 11262 and the cartridge 11264 in various instances. Referringprimarily to FIGS. 157 and 158, the separable portions 11366 a and 11366b can be held together by a lock 11390 when the lock 11390 is in alocked condition, as illustrated in FIG. 158. Correspondingly, when thelock 11390 is in an unlocked condition, the separable portions 11366 aand 11366 b can move relative to one another. The separable portion11366 a of the firing member 11366 can comprise a first lateral portion11363 a, a second lateral portion 11367 a, and a cutting member portion11365 a positioned intermediate the lateral portions 11363 a and 11367a. In various circumstances, the lateral portions 11363 a and 11367 acan be retained to the cutting member portion 11365 a via one or morepins, not illustrated in FIGS. 157 and 158, extending through apertures11396 a defined therein. The separable portion 11366 b of the firingmember 11366 can comprise a first lateral portion 11363 b, a secondlateral portion 11367 b, and a cutting member portion 11365 b positionedintermediate the lateral portions 11363 b and 11367 b. In variouscircumstances, the lateral portions 11363 b and 11367 b can be retainedto the cutting member portion 11365 b via at least one retention member,not illustrated in FIGS. 157 and 158, engaged with a foot 11396 bextending therefrom. As the reader will appreciate, the aforementionedretention pins hold the various components of the separable portion11363 a together while the aforementioned retention member holds thevarious components of the separable portion 11363 b together. As thereader will also appreciate, the lock 11390, when in its lockedposition, holds the separable portions 11363 a and 11363 b together. Invarious instances, referring primarily to FIG. 158, the lock 11390 caninclude a first lock member 11397 a configured to engage a first lockportion 11361 a of the first cutting member portion 11365 a and, inaddition, a second lock member 11397 b configured to engage a secondlock portion 11361 b of the second cutting member portion 11365 b. Thefirst lock portion 11361 a and the second lock portion 11361 b can beconfigured to co-operatively and releasably hold the cutting memberportions 11365 a and 11365 b together. In various instances, the lockportions 11397 a, 11397 b can hold the cutting member portions 11365 aand 11365 b together such that cutting surfaces 11395 a and 11395 b ofthe cutting member portions 11365 a and 11365 b, respectively, form acontinuous, or at least substantially continuous, cutting surface.Referring once again to FIG. 158, the lock portions 11397 a, 11397 b ofthe lock 11390 can be configured to co-operatively engage and hold keys11361 a and 11361 b of cutting member portions 11365 a and 11365 b,respectively. In various instances, the lock portions 11397 a, 11397 bcan define a recess 11398 therebetween which is configured to receivekeys 11361 a and 11361 b when the lock 11390 is in its locked position.When the lock 11390 is pulled proximally, the lock portions 11397 a and11397 b can disengage the keys 11361 a and 11361 b. At such point, thelock 11390 may no longer hold the cutting member portions 11365 a and11365 b together. In such circumstances, as a result, the separableportions 11366 a and 11366 b can move relative to each other. Forinstance, the separable portion 11366 a can move with the jaw 11262 whenthe jaw 11262 is re-opened and, correspondingly, the separable portion11366 b can remain with the cartridge 11264. In view of the above, thelock 11390 can be pulled proximally to unlock the separable portions11366 a and 11366 b when the firing member 11366 becomes stuck in an atleast partially fired position, for example.

As discussed above, the lock 11390 can be pulled proximally to unlockthe separable portions 11366 a and 11366 b of the firing member 11366.Turning now to FIG. 159, the lock 11390 can be pulled proximally and/orpushed distally by lock bar 11391. The lock bar 11391 can be positionedwithin the end effector 11360 and can include a proximal end 11392 and adistal end 11393. The distal end 11393 of the lock bar 11391 can beengaged with the lock 11390. More specifically, in at least oneembodiment, the distal end 11393 can include a projection extendingtherefrom which can be slidably positioned within an elongate slot 11399defined in the lock 11390. In order to pull the lock 11390 proximally,the lock bar 11391 can be pulled proximally until the projectioncontacts the proximal end 11394 of the elongate slot 11399 wherein themotion of the lock bar 11391 can be transferred to the lock 11390.Correspondingly, the projection can be configured to contact a distalend 11395 of the elongate slot 11399 in order to push the lock 11390distally. As the reader will appreciate, referring again to FIG. 156,the firing member 11366 can one or more include longitudinal slots 11369defined therein which can be configured to permit the lock barprojection to extend therethrough and engage the lock 11390 as describedabove.

Further to the above, referring primarily to FIGS. 156 and 160, theproximal end 11392 of the lock bar 11391 can comprise an attachmentportion configured to be engaged by a lock actuator 11348 of a shaft11340 of a surgical instrument. Referring primarily to FIG. 160, thelock actuator 11348 can comprise a distal end 11349 including a notch,for example, which can be configured to receive the proximal end 11392of the lock bar 11391. The lock actuator 11348 can further comprise aproximal end 11347 which can be pulled proximally and/or pushed distallyby a user of the surgical instrument in order to move the lock actuator11348 and the lock bar 11391 proximally and/or distally, respectively.In use, the proximal end 11392 of the lock bar 11391 can be assembled tothe distal end 11349 of the lock actuator 11348 when the end effector11360 is assembled to the shaft 11340.

As outlined above, a motor can be utilized to advance and/or retract afiring member to deploy fasteners from an end effector and/or incisetissue captured within the end effector. In various instances, the motorcan include a rotatable drive shaft, the rotation of which can beconverted to translational movement and transmitted to a firing member,such as a cutting member and/or staple driver, for example. In at leastone such instance, the rotatable drive shaft can include a threadedportion which is threadably engaged with a collar including a threadedaperture defined therein wherein, in use, the collar can be constrainedfrom rotating such that the rotation of the drive shaft advances thecollar distally and/or retracts the collar proximally depending on thedirection in which the drive shaft is rotated. In certain instances, thefiring member may become stuck and/or otherwise experience a force, ortorque, which exceeds a desired, or predetermined maximum, force, ortorque. Turning now to FIGS. 162-167, a motor assembly 12000 can includea motor 12010, a shaft 12020, and a slip clutch assembly 12030, whereinthe slip clutch assembly 12030 can limit the force, or torque, that themotor 12010 can transmit to the shaft 12020. In various instances,referring primarily to FIGS. 162 and 163, the slip clutch assembly 12030can transmit torque between a rotatable drive output 12012 of the motor12010 and the shaft 12020. Referring now to FIGS. 165-167, the driveoutput 12012 can include a substantially circular outer profile portion12011 and a transition surface 12014, which can be flat, or at leastsubstantially flat, in various instances. The outer profile of the driveoutput 12012 can further include a first drive shoulder 12016 definedbetween the circular profile portion 12011 and the flat surface 12014and, in addition, a second drive shoulder 12018 which is defined betweenthe opposite end of the flat surface 12014 and the circular profileportion 12011.

As also illustrated in FIGS. 165-167, the slip clutch assembly 12030 caninclude a drive element 12034 which is biased into engagement with thedrive output 12012 by a biasing element, or spring, 12036. The driveelement 12034 can be at least partially positioned within a retentionslot defined in a housing 12037 of the slip clutch assembly 12030 suchthat the movement of the drive element 12034 relative to the housing12037 can be defined along an axis. As the reader will appreciate, thehousing 12037 of the slip clutch assembly can be mounted to the shaft12020 such that the housing 12037 and the shaft 12020 rotate togethersynchronously. As the reader will also appreciate, the drive element12034 can transmit the rotational motion of the drive output 12012 tothe housing 12037, at least in certain circumstances. More specifically,when the drive output 12012 is rotated in a first direction, asindicated by arrow 12017, to advance the firing member distally, thedrive output 12012 can rotate relative to the drive element 12034 untilthe first drive shoulder 12016 comes into contact with the drive element12034. As the reader will appreciate, the first drive shoulder 12016 canremain in contact with the drive element 12034 so long as the biasingmember 12036 is able to resist, or at least sufficiently resist, theradially outward movement of the drive element 12034. So long as thedrive element 12034 is in contact with the first drive shoulder 12016,the motor 12010 can rotate the shaft 12020 in a direction which advancesthe firing member distally. In various instances, the motor 12010 mayapply a torque to the drive output 12012 which is large enough todisplace the drive element 12034 radially outwardly such that the firstdrive shoulder 12016 of the drive output 12012 slips by the driveelement 12034 and, as a result, the drive output 12012 rotates relativeto the drive element 12034, the slip clutch housing 12037, and the shaft12020. Stated another way, the drive element 12034 can be defeated andoperably disengaged from the motor 12010 when the torque applied to thedrive output 12012 exceeds a predetermined, or maximum, torque. When thetorque applied to the drive output 12012 falls below this predetermined,or maximum, torque, the drive element 12034 can re-engage the firstdrive shoulder 12016 and, as a result, the shaft 12020 can be operablyre-engaged with the motor 12010 such that the shaft 12020 is rotated bythe drive output 12012 of the motor 12010.

Further to the above, when the drive output 12012 is rotated in a seconddirection, as indicated by arrow 12019, to retract the firing memberproximally, the drive output 12012 can rotate relative to the driveelement 12034 until the second drive shoulder 12018 comes into contactwith the drive element 12034. As the reader will appreciate, the seconddrive shoulder 12018 can remain in contact with the drive element 12034so long as the biasing member 12036 is able to resist, or at leastsufficiently resist, the radially outward movement of the drive element12034. So long as the drive element 12034 is in contact with the seconddrive shoulder 12018, the motor 12010 can rotate the shaft 12020 in adirection which retracts the firing member proximally. In variousinstances, the motor 12010 may apply a torque to the drive output 12012which is large enough to displace the drive element 12034 radiallyoutwardly such that the second drive shoulder 12018 of the drive output12012 slips by the drive element 12034 and, as a result, the driveoutput 12012 rotates relative to the drive element 12034, the slipclutch housing 12037, and the shaft 12020. Stated another way, the driveelement 12034 can be defeated and operably disengaged from the motor12010 when the torque applied to the drive output 12012 exceeds apredetermined, or maximum, torque. When the torque applied to the driveoutput 12012 falls below this predetermined, or maximum, torque, thedrive element 12034 can re-engage the second drive shoulder 12018 and,as a result, the shaft 12020 can be operably re-engaged with the motor12010 such that the shaft 12020 is rotated by the drive output 12012 ofthe motor 12010.

In various instances, further to the above, the first drive shoulder12016 and the second drive shoulder 12018 can comprise the sameconfiguration. In certain instances, the first drive shoulder 12016 canbe defined by a first radius of curvature and the second drive shoulder12018 can be defined by a second radius of curvature. In some instances,the first radius of curvature can be the same as the second radius ofcurvature. In such instances, the maximum, or slip, torque that themotor 12010 can apply when rotating the drive output 12012 in the firstdirection 12017 can be the same, or substantially the same, as themaximum, or slip, torque that the motor 12010 can apply when rotatingthe drive output 12012 in the second direction 12019. In some instances,the first radius of curvature can be different than the second radius ofcurvature. In such instances, the maximum, or slip, torque that themotor 12010 can apply when rotating the drive output 12012 in the firstdirection 12017 can be different than the maximum, or slip, torque thatthe motor 12010 can apply when rotating the drive output 12012 in thesecond direction 12019. In at least one such instance, the first radiusof curvature can be larger than the second radius of curvature wherein,as a result, the maximum, or slip, torque in the first direction 12017can be less than the maximum, or slip, torque in the second direction12019. Stated another way, the motor 12010 can apply a larger torque tothe shaft 12020 when retracting the firing element than when advancingthe firing element. Such instances may be advantageous when it may bedesirable to retract the firing element so that the end effector of thesurgical instrument can be re-opened and unclamped from the tissue, forexample. In at least one instance, the first radius of curvature can besmaller than the second radius of curvature wherein, as a result, themaximum, or slip, torque in the first direction 12017 can be greaterthan the maximum, or slip, torque in the second direction 12019. Statedanother way, the motor 12010 can apply a larger torque to the shaft12020 when advancing the firing element than when retracting the firingelement.

Further to the above, referring primarily to FIGS. 163 and 164, thebiasing member 12036 can be resiliently supported by a spring collar12032 positioned within a circumferential channel 12031 defined in theslip clutch housing 12037. In such instances, the spring collar 12032and the biasing member 12036 can co-operate to apply a radially inwardbiasing force and/or to resist the radially outward movement of thedrive element 12034. The spring collar 12032, in various instances, cancomprise an annular body including a first free end 12033 and a secondfree end 12034, wherein the annular body can resiliently expand when theradially outward force discussed above is applied thereto andresiliently contract when that radially outward force has ceased ordiminished. In such instances, the first free end 12033 of the springcollar 12032 can move relative to the second free end 12034.

The devices disclosed herein can be designed to be disposed of after asingle use, or they can be designed to be used multiple times. In eithercase, however, the device can be reconditioned for reuse after at leastone use. Reconditioning can include any combination of the steps ofdisassembly of the device, followed by cleaning or replacement ofparticular pieces, and subsequent reassembly. In particular, the devicecan be disassembled, and any number of the particular pieces or parts ofthe device can be selectively replaced or removed in any combination.Upon cleaning and/or replacement of particular parts, the device can bereassembled for subsequent use either at a reconditioning facility, orby a surgical team immediately prior to a surgical procedure. Thoseskilled in the art will appreciate that reconditioning of a device canutilize a variety of techniques for disassembly, cleaning/replacement,and reassembly. Use of such techniques, and the resulting reconditioneddevice, are all within the scope of the present application.

Preferably, the invention described herein will be processed beforesurgery. First, a new or used instrument is obtained and if necessarycleaned. The instrument can then be sterilized. In one sterilizationtechnique, the instrument is placed in a closed and sealed container,such as a plastic or TYVEK bag. The container and instrument are thenplaced in a field of radiation that can penetrate the container, such asgamma radiation, x-rays, or high-energy electrons. The radiation killsbacteria on the instrument and in the container. The sterilizedinstrument can then be stored in the sterile container. The sealedcontainer keeps the instrument sterile until it is opened in the medicalfacility.

Any patent, publication, or other disclosure material, in whole or inpart, that is said to be incorporated by reference herein isincorporated herein only to the extent that the incorporated materialsdoes not conflict with existing definitions, statements, or otherdisclosure material set forth in this disclosure. As such, and to theextent necessary, the disclosure as explicitly set forth hereinsupersedes any conflicting material incorporated herein by reference.Any material, or portion thereof, that is said to be incorporated byreference herein, but which conflicts with existing definitions,statements, or other disclosure material set forth herein will only beincorporated to the extent that no conflict arises between thatincorporated material and the existing disclosure material.

While this invention has been described as having exemplary designs, thepresent invention may be further modified within the spirit and scope ofthe disclosure. This application is therefore intended to cover anyvariations, uses, or adaptations of the invention using its generalprinciples. Further, this application is intended to cover suchdepartures from the present disclosure as come within known or customarypractice in the art to which this invention pertains.

What is claimed is:
 1. A surgical stapler, comprising: an end effectorcomprising a plurality of deployable staples and a firing element; amotor configured to drive said firing element, wherein said motorcomprises a primary set of coils and a secondary set of coils; and acontrol system in signal communication with said motor, wherein saidcontrol system comprises: a battery; a pulse width modulation circuitconfigured to control the duration of current pulses supplied from saidbattery to said motor; and a switch configured to switch the electricmotor between a plurality of operating states, wherein the plurality ofoperating states comprises: a first operating state in which the primaryset of coils are configured to drive said firing element; and a secondoperating state in which said primary set of coils and said secondaryset of coils are configured to drive said firing element.
 2. Thesurgical stapler of claim 1, wherein the battery supplies current pulsesto said primary set of coils at a voltage that corresponds to themaximum torque of said primary set of coils during the first operatingstate.
 3. The surgical stapler of claim 2, wherein a surplus current issupplied to said secondary set of coils during the second operatingstate.
 4. The surgical stapler of claim 3, wherein said control systemmaximizes the surplus current supplied to said secondary set of coilsduring the second operating state based on the volt-ampere limit of saidbattery.
 5. The surgical instrument of claim 1, wherein said motorgenerates a first amount of torque during the first operating state,wherein said motor generates a second amount of torque during the secondoperating state, and wherein the second amount of torque is greater thanthe first amount of torque.
 6. The surgical stapler of claim 5, whereinsaid motor drives said firing element in a first direction during thefirst operating state, wherein said motor drives said firing element ina second direction during the second operating state, and wherein thesecond direction is opposite to the first direction.
 7. The surgicalstapler of claim 6, wherein the first direction comprises a distallyadvancing direction, and wherein the second direction comprises aproximally retracting direction.
 8. The surgical stapler of claim 1,wherein said motor comprises a stepper motor.
 9. A surgical stapler,comprising: an end effector comprising a plurality of deployable staplesand a firing element; a control system, comprising: a battery; and apulse width modulation circuit configured to control the duration ofcurrent pulses supplied from said battery; and a motor in signalcommunication with said control system and configured to drive saidfiring element, wherein said motor comprises: a primary set of coilsconfigured to generate a first amount of torque, wherein the firstamount of torque drives said firing element in a first direction; and asecondary set of coils configured to generate a second amount of torque,wherein the first amount of torque and the second amount of torque drivesaid firing element in a second direction.
 10. The surgical stapler ofclaim 9, wherein said battery is configured to supply current pulses tosaid primary set of coils at a voltage that corresponds to the maximumtorque of said primary set of coils.
 11. The surgical stapler of claim10, wherein said battery operably supplies a surplus current to saidsecondary set of coils.
 12. The surgical stapler of claim 9, whereinsaid control system maximizes the torque generated by said primary setof coils and the secondary set of coils when driving said firing elementin the second direction.
 13. The surgical stapler of claim 9, whereinthe second direction is opposite to the first direction.
 14. Thesurgical stapler of claim 5, wherein the second direction comprises aproximal direction.
 15. The surgical stapler of claim 1, wherein saidmotor comprises a stepper motor.
 16. A surgical stapler, comprising: anend effector comprising a plurality of deployable staples and a firingelement; a motor configured to drive said firing element, wherein saidmotor comprises a primary set of coils; and a control system in signalcommunication with said motor, wherein said control system comprises: abattery; and a pulse width modulation circuit configured to control theduration of current pulses supplied from said battery to said primaryset of coils.
 17. The surgical stapler of claim 16, wherein said motorfurther comprises a secondary set of coils, and wherein said controlsystem comprises a switch configured to operably supply current fromsaid battery to said secondary set of coils.
 18. The surgical stapler ofclaim 17, wherein said battery supplies current to said primary set ofcoils during a first operating state, and wherein said battery suppliescurrent to said primary set of coils and said secondary set of coilsduring a second operating state.
 19. The surgical stapler of claim 18,wherein said motor drives said firing element distally during the firstoperating state, and wherein said motor drives said firing elementproximally during the second operating state.
 20. The surgical staplerof claim 16, wherein said control system optimizes the torque generatedby said motor.
 21. The surgical stapler of claim 16, wherein said motorcomprises a stepper motor.